Subaru

Foreword
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing maintenance, repair or diagnosis of Subaru LEGACY. Applicable model: 2009MY BL*****, BP***** The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc. may be made without notice.
FW-2
How to Use This Manuals

HOW TO USE THIS MANUALS
1. How to Use This Manuals

A: HOW TO USE THIS MANUALS
1. STRUCTURE
Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and the diagnostic information has also been added where necessary.
2. CONTENTS
The first page has an index with tabs.
HU-2

3. COMPONENT
Illustrations are provided for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order parts, refer to parts catalogue. Example:
T3
(3) (6) (5) (7)
T2 T3
(2) T8 T6 T10 T5 (1) (2) (6) T4 (4) (9) T6 (3) (7) T2 T11 T6 (22) T5 (3) (12) T4 (10) (23) T2 (14) T7 (24) (13) T2 (10) (16) (17) (18) T3 T1 (21) T1 (28) T4
: Selective part : Replacement part : Sealing point
(4) (8) (20) (21) T3 T3 (12) (22) (23) (16) (14) (18) (13) (15) (17) (19) T1 T3
T1 (5) T2 T2
(1)
(9) (10) (11) T2
(4)
(3) (10)
(11)
(4)
(10) (4)
T4
(15)
(35) (27) (26) T5 (34) T3
(8) T2 (24)
(25)
(25) (30)
(36) (31) T5 (29) (37) (32) (33)
: Should be lubricated with oil.
(20) T9 (19) T1 ,
: Should be lubricated with grease.
T2
....
: Tightening torque
HU-00017
HU-3

4. SPECIFICATION
If necessary, specifications are also included.
5. INSPECTION
Inspections to be carried out before and after maintenance are included.
6. MAINTENANCE
Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure. If many serviceable parts are included in one service procedure, appropriate reference is provided for each parts. Example:
15.Main Shaft Assembly for Single-Range

A: REMOVAL
1) Remove the manual transmission assembly from vehicie. <Ref. to MT-33, REMOVAL, Manual Transmission Assembly.>
(A)
(B)
(C)
11) Tighten the lock nuts to the specified torque using ST1 and ST2. NOTE: Secure the lock nuts in two places after tightening. ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH (35)
(E) (F) (D)
Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb)
(G)
(H)
ST2
ST1
HU-00020
(A) (B) (C)
Component Process Reference
(D) (E) (F)
Cautions Tool number of special tool Name of special tool
(G) (H)
Tightening torque Illustration
HU-4

7. DIAGNOSIS
Tables showing a step-by-step process make it easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included. Example: Tightening torque: 44 Nm (4.5 kgf-m, 33 ft-lb)
Item Force Mass (Weight) Capacity Torque Rotating speed Pressure Power Calorie Fuel consumption rate SI units N (Newton) kg, g 2, m2 or cm3 Nm rpm kPa (kilopascal) W Wh g/kwh Conventional unit kgf kg, g 2or cc kgf-m, kgf-cm rpm kgf/cm2 mmHg PS cal g/PSh Remarks 1 kgf = 9.80655 N 1 cc = 1 cm3 = 1 m2 1 kgf-m = 9.80655 Nm 1 kgf/cm2 = 98.0655 kPa 1 mmHg = 0.133322 kPa 1 PS = 0.735499 kW 1 kcal = 1.16279 Wh 1 g/PSh = 1.3596 g/kWh
The figure used in these manuals are described in the SI units and conventional units are described in (
).
HU-5

9. EXPLANATION OF TERMINOLOGY
List
AAI A/B ABS A/C ADA A/F ALT APS ASSY AT ATF AVCS AWD BATT BJ CAN CD COMPL CPU DOHC DOJ DTC EBJ ECM EDJ EGI E/G EGR ETC EX F/B Ft FWD GPS HID : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : Air Assist Injection Airbag Anti-lock Brake System Air Conditioner Active Driving Assist Air Fuel Ratio Generator Accessory power supply socket Assembly Automatic Transmission Automatic Transmission Fluid Active Valve Control System All Wheel Drive Battery Bell Joint Communication Area Network Compact Disc Complete Central Processing Unit Double Overhead Camshaft Double Offset Joint Diagnostic code High-Efficiency Compact Ball Fixed Joint Engine Control Module High-Efficiency Compact Double Offset Joint Electronic Gasoline Injection Engine Exhaust Gas Recirculation Electronic Throttle Control Exhaust Fuse & Joint Box Front Front Wheel Drive Global Positioning System High-Intensity Discharge H/U HVAC IG IN INT I/O ISC LAN LH LSD M/B MID MFI MP-T MT NA OP PC PCV P/S PTJ P/W RH Rr SDI SI-DRIVE SOHC SRS ST SW TCS TGV VDC VTD : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : Hydraulic Unit Heater, Ventilator and Air Conditioner Ignition Intake Intermittent Input / Output Idle Speed Control Local Area Network LH (Left Hand) Limited Slip Differential Main Fuse & Relay Box Multi-information Display Multi Point Injection Multi-Plate Transfer Manual Transmission Natural Aspiration Option Parts Personal Computer Positive Crankcase Ventilation Power Steering Pillow Tripod Joint Power Window RH (Right Hand) Rear SUBARU Diagnostic Interface SUBARU Intelligent Drive Single Overhead Camshaft Supplemental Restraint System Special Tool Switch Traction Control System Tumble Generator Valve Vehicle Dynamics Control Variable Torque Distribution
HU-6
LEGACY
SPECIFICATIONS
1. LEGACY
A: DIMENSION
1. SEDAN MODEL
Model Overall length Overall width Overall height (at C.W.) Compartment Wheelbase Front Rear Minimum road clearance Tread
*1: *2:
2.5 L SOHC mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
1,425 (56.1)
2.5 L DOHC turbo 4,700 (185.0) 1,730 (68.1) 1,425 (56.1), 1,435 (56.5)*2 1,900 (74.8) 1,445 (56.9) 1,165 (45.9), 1,100 (43.3)*1 2,670 (105.1) 1,495 (58.9) 1,485 (58.5) 150 (5.9), 160 (6.3)*2
3.0 L DOHC
1,435 (56.5)
Length Width Height
150 (5.9)
160 (6.3)
With sunroof 2.5 GT spec. B model
2. WAGON MODEL
Model Overall length Overall width Overall height (at C.W.) Length Compartment Width Height Wheelbase Front Tread Rear Minimum road clearance
*1:
2.5 L DOHC turbo 4,785 (188.4) 1,730 (68.1) 1,475 (58.1) 1,840 (72.4) 1,445 (56.9) 1,190 (46.9), 1,145 (45.1)*1 2,670 (105.1) 1,495 (58.9) 1,485 (58.5)
150 (5.9)
155 (6.1)
With sunroof
SPC-2
LEGACY
SPECIFICATIONS
B: ENGINE
Model Engine type Valve arrangement Bore stroke Displacement Compression ratio Ignition order Idle speed at Park or Neutral position Maximum output Maximum torque mm (in) cm3 (cu in) 10.0 1324 rpm kW (HP)/rpm Nm (kgf-m, ft-lb)/rpm 650 (MT) 700 (AT) 125 (170)/6,000 230 (23.5, 170)/4,400 750 184 (243)/6,000 327 (33.3, 241)/3,600 2.5 L SOHC 2.5 L DOHC turbo Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Overhead camshaft 99.5 79.0 (3.917 3.110) 2,457 (149.9) 8.4 89.2 80.0 (3.512 3.150) 3,000 (183.06) 10.7 163254 650 185 (245)/6,600 291 (29.7, 215)/4,200 3.0 L DOHC Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine
C: ELECTRICAL
Model Ignition timing (at idling) Spark plug Generator Battery Type and manufacturer Type and capacity (5HR) MT AT BTDC 2.5 L SOHC MT: 10 AT: 15 NGK: FR5AP-11 2.5 L DOHC turbo MT: 12 AT: 17 NGK: SILFR6A 12 V 110 A 12V 48AH (55D23L) 12V 52AH (75D23L) 3.0 L DOHC 15 NGK: ILFR6B
SPC-3
LEGACY
SPECIFICATIONS
D: TRANSMISSION
1. MT
Model Transmission type Clutch type 1st 2nd 3rd 4th 5th 6th Rev. Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio 2.5 L SOHC 5MT DSPD 3.454 2.062 1.448 1.088 0.780 3.333 Hypoid 3.900 Helical 1.000 Hypoid 3.900 2.5 L DOHC turbo 5MT DSPD 3.166 1.882 1.296 0.972 0.738 3.333 Hypoid 3.900 Helical 1.000 Hypoid 3.900 6MT DSPD 3.636 2.235 1.521 1.137 0.891 0.707 3.545 Hypoid 3.900 Helical 1.100 Hypoid 3.545
Gear ratio
Reduction gear (Front) Transfer reduction Final reduction
Reduction gear (Rear)
5MT: 5-forward speeds with synchromesh and 1-reverse 6MT: 6-forward speeds with synchromesh and 1-reverse DSPD: Dry Single Plate Diaphragm
2. AT
Model Transmission type Clutch type 1st 2nd Gear ratio 3rd 4th 5th 6th Rev. Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio 2.5 L SOHC 4AT TCC 2.785 1.545 1.000 0.694 2.272 Helical 1.000 Hypoid 4.111 Hypoid 4.111 2.5 L DOHC turbo 5AT TCC 3.540 2.264 1.471 1.000 0.834 2.370 Helical 1.000 Hypoid 3.083 Hypoid 3.083 3.0 L DOHC 3.0 R 3.0 R LTD 5AT TCC 3.540 2.264 1.471 1.000 0.834 2.370 Helical 1.000 Hypoid 3.083 Hypoid 3.083 3.272 3.272
Reduction gear (Front)
1st reduction Final reduction
4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse TCC: Torque Converter Clutch
SPC-4
LEGACY
SPECIFICATIONS
E: STEERING
Model Type Turns, lock to lock Minimum turning diameter Curb to curb m (ft) Wall to wall 2.5 L SOHC 2.5 L DOHC turbo GT spec. B GT Rack and pinion 2.6 2.8 11.6 (38.0) 10.8 (35.4) 12.4 (40.7) 11.6 (35.4) 3.0 L DOHC 3.0 R LTD 3.0 R 2.6 11.6 (38.0) 12.4 (40.7) 2.8 10.8 (35.4) 11.6 (35.4)
3.2 10.8 (35.4) 11.6 (38.1)
F: SUSPENSION
Front Rear Macpherson strut type suspension Multi-link type suspension
G: BRAKE
Model Service brake system Front Rear Parking brake 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Ventilated disc brake Mechanical on rear brakes
H: TIRE
Model Wheel size Tire size Type 2.5 L SOHC Except CanCanada model ada model 16 6 1/2JJ 17 7JJ P205/55 R16 89H P205/50 R17 88V 2.5 L DOHC turbo 2.5 GT spec. Except 2.5 GT B spec.B 18 7JJ 17 7JJ 215/45 R18 215/45 R17 89Y 91W Tubeless, Steel belted radial 3.0 L DOHC 3.0 R 17 7JJ 215/45 R17 91W 3.0 R LTD 18 7JJ P215/45 R18 89W
I:
CAPACITY
2.5 L SOHC 5MT 4AT 2 (US gal, Imp gal) Total capacity (Overhaul) 2 (US qt, Imp qt) When replacing engine oil and oil filter When replacing engine oil only 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5) 4.2 (4.4, 3.7) 2.5 L DOHC turbo 5MT 5AT 64 (16.9, 14.1) 5.0 (5.3, 4.4) 4.3 (4.5, 3.8) 4.0 (4.2, 3.5) 3.5 (3.7, 3.1) 9.3 (9.8, 8.2) 1.2 (1.3, 1.1) 3.5 (3.7, 3.1) 9.8 (10.4, 8.6) 1.4 (1.5, 1.2) 4.1 (4.3, 3.6) 1.0 (1.1, 0.9) 7.3 (7.7, 6.4) 6MT 3.0 L DOHC 5AT 7.0 (7.4, 6.2) 5.7 (6.0, 5.0) 5.5 (5.8, 4.8) 9.8 (10.4, 8.6) 1.4 (1.5, 1.2) 0.8 (0.8, 0.7) 7.2 (7.6, 6.3)
Model Fuel tank
Engine oil
Filling amount of engine oil 2 (US qt, Imp qt)
Transmission gear oil ATF Front differential gear oil Rear differential gear oil Power steering fluid Engine coolant
0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 7.3 7.2 (7.7, 6.4) (7.6, 6.3)
SPC-5
LEGACY
SPECIFICATIONS
J: WEIGHT
1. US MODEL
Sedan 2.5 L Non-turbo Model 2.5 i BASE 5MT Destination code OP code Front Curb weight (C.W.) Rear Total Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.) Front Rear Total kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) 821 (1,810) 664 (1,465) 1,485 (3,275) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) DC 841 (1,855) 669 (1,475) 1,510 (3,330) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) 825 (1,819) 673 (1,483) 1,498 (3,302) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) 4AT 2.5 i 5MT U5, U6 DW 845 (1,864) 677 (1,493) 1,522 (3,357) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) 4AT 2.5 i Limited 4AT EW 854 (1,884) 682 (1,503) 1,536 (3,387) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325)
Option
Vehicle dynamics control Power package Side airbag Curtain airbag Sunroof Navigation system Dark colored glass
SPC-6
LEGACY
SPECIFICATIONS
Sedan 2.5 L Turbo Model 5MT Destination code OP code Front Curb weight (C.W.) Rear Total Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.) Front Rear Total kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) 3W 872 (1,922) 683 (1,506) 1,555 (3,428) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) EW 901 (1,987) 688 (1,516) 1,589 (3,503) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 2.5 GT LTD 5AT EK 903 (1,992) 688 (1,516) 1,591 (3,508) 1,040 (2,295) 1,060 (2,340) 2,010 (4,535) 2.5 GT spec. B 6MT U4 EK 912 (2,012) 694 (1,531) 1,607 (3,543) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 3.0 L Non-turbo 3.0 R 3.0 R LTD 5AT DW 911 (2,008) 682 (1,503) 1,592 (3,511) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) EW 926 (2,042) 685 (1,511) 1,611 (3,553) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) EK 928 (2,047) 685 (1,511) 1,614 (3,558) 1,040 (2,295) 1,060 (2,340) 2,010 (4,535)
Option
SPC-7
LEGACY
SPECIFICATIONS
2. CANADA MODEL
Sedan 2.5 L Non-turbo Model 2.5 i 5MT Destination code OP code Front Curb weight (C.W.) Rear Total Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.) Front Rear Total kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) C0 DW 828 (1,826) 678 (1,495) 1,506 (3,321) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) C5 UC 812 (1,790) 660 (1,455) 1,472 (3,246) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) C0 DW 848 (1,870) 682 (1,504) 1,530 (3,374) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) 4AT C5 UC 832 (1,835) 664 (1,464) 1,496 (3,299) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) 2.5 L Turbo 2.5 GT spec. B 6MT EK 913 (2,013) 695 (1,532) 1,608 (3,546) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) C0 EW 913 (2,013) 684 (1,508) 1,597 (3,521) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 3.0 L Non-turbo 3.0 R 5AT EK 916 (2,020) 684 (1,508) 1,600 (3,528) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435)
Option
SPC-8
LEGACY
SPECIFICATIONS
Wagon 2.5 L Non-turbo 2.5 i 5MT Destination code OP code Front Curb weight (C.W.) Rear Total Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.) Front Rear Total kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) C0 DW 823 (1,815) 697 (1,537) 1,520 (3,352) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) C5 UC 806 (1,777) 670 (1,477) 1,476 (3,255) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) C0 DW 843 (1,859) 697 (1,537) 1,540 (3,396) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325) 4AT C5 UC 826 (1,821) 670 (1,477) 1,496 (3,299) 1,040 (2,295) 1,060 (2,340) 1,960 (4,325)
Model
Vehicle dynamics control Power package Option Side airbag Curtain airbag Sunroof Navigation system Dark colored glass
SPC-9
OUTBACK
SPECIFICATIONS
2. OUTBACK
A: DIMENSION
1. WAGON MODEL
Model Overall length Overall width Overall height (at C.W.) Length Compartment Width Height Wheelbase Front Tread Rear Minimum road clearance
*1:
215 (8.5)
2.5 L DOHC turbo 4,800 (189.0) 1,770 (69.7) 1,605 (63.2) 1,840 (72.4) 1,445 (56.9) 1,190 (46.9), 1,145 (45.1)*1 2,670 (105.1) 1,495 (58.9) 1,490 (58.7) 220 (8.7)
3.0 L DOHC
215 (8.5)
With sunroof
B: ENGINE
Model Engine type Valve arrangement Bore stroke mm (in) Displacement cm3 (cu in) Compression ratio Ignition order Idle speed at Park or Neutral rpm position Maximum kW (HP)/rpm output Maximum Nm (kgf-m, ft-lb)/rpm torque 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine 89.2 80.0 (3.512 3.150) 3,000 (183.06) 10.7 163254 650 185 (245)/6,600 291 (29.7, 215)/4,200 Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Overhead camshaft 99.5 79.0 (3.917 3.110) 2,457 (149.9) 10.0 8.4 1324 650 (MT) 700 (AT) 125 (170)/6,000 230 (23.5, 170)/4,400 750 184 (243)/6,000 327 (33.3, 241)/3,600
C: ELECTRICAL
Model Ignition timing (at idling) Spark plug Generator Battery BTDC 2.5 L SOHC MT: 10 AT: 15 NGK: FR5AP-11 2.5 L DOHC turbo MT: 12 AT: 17 NGK: SILFR6A 12 V 110 A 12V 48AH (55D23L) 12V 52AH (75D23L) 3.0 L DOHC 15 NGK: ILFR6B
Type and manufacturer Type and capacity (5HR) MT AT
SPC-10
OUTBACK
SPECIFICATIONS
D: TRANSMISSION
1. MT
Model Transmission type Clutch type 1st 2nd 3rd 4th 5th Rev. Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio 2.5 L SOHC 5MT DSPD 3.454 2.062 1.448 1.088 0.825 3.333 Hypoid 4.111 Helical 1.000 Hypoid 4.111 2.5 L DOHC turbo 5MT DSPD 3.166 1.882 1.296 0.972 0.738 3.333 Hypoid 4.444 Helical 1.000 Hypoid 4.444
Gear ratio
Reduction gear (Front) Transfer reduction Final reduction
5MT: 5-forward speeds with synchromesh and 1-reverse DSPD: Dry Single Plate Diaphragm
2. AT
Model Transmission type Clutch type 1st 2nd 3rd 4th 5th Rev. Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio 2.5 L SOHC 4AT TCC 2.785 1.545 1.000 0.694 2.272 Helical 1.000 Hypoid 4.444 Hypoid 4.444 2.5 L DOHC turbo 5AT TCC 3.540 2.264 1.471 1.000 0.834 2.370 Helical 1.000 Hypoid 3.272 Hypoid 3.272 3.0 L DOHC 5AT TCC 3.540 2.264 1.471 1.000 0.834 2.370 Helical 1.000 Hypoid 3.272 Hypoid 3.272
Gear ratio
Reduction gear (Front)
1st reduction Final reduction
4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse TCC: Torque Converter Clutch
E: STEERING
Model Type Turns, lock to lock Minimum turning diameter m (ft) Curb to curb Wall to wall 2.5 L SOHC 2.5 L DOHC turbo Rack & pinion 3.2 10.8 (35.4) 11.6 (38.1) 3.0 L DOHC
SPC-11
OUTBACK
SPECIFICATIONS
F: SUSPENSION
Front Rear Macpherson strut type suspension Multi-link type suspension
G: BRAKE
Model Service brake system Front Rear Parking brake 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Mechanical on rear brakes
H: TIRE
Model Wheel size Tire size Type
*1:
2.5L SOHC BASE 16 61/2JJ P225/60 R16 97H
2.5 L SOHC
2.5 L DOHC turbo
3.0 L DOHC
16 61/2JJ*1, 17 7JJ 17 7JJ 17 7JJ P225/60 R16 97H*1, P225/55 R17 95V Tubeless, Steel belted radial
2.5 L SOHC model for Canada
I:
CAPACITY
2.5 L SOHC 5MT 4AT 2 (US gal, Imp gal) Total capacity (Overhaul) 2 (US qt, Imp qt) 2.5 L DOHC turbo 5MT 5AT 64 (16.9, 14.1) 3.0 L DOHC 5AT
Model Fuel tank
5.0 (5.3, 4.4)
7.0 (7.4, 6.2) 5.7 (6.0, 5.0) 5.5 (5.8, 4.8) 9.8 (10.4, 8.6) 1.4 (1.5, 1.2)
Engine oil
Filling amount of engine oil 2 (US qt, Imp qt)
Transmission gear oil ATF Front differential gear oil Rear differential gear oil Power steering fluid Engine coolant
When replacing 4.2 (4.4, 3.7) 4.3 (4.5, 3.8) engine oil and oil filter When replacing 4.0 (4.2, 3.5) engine oil only 2 (US qt, Imp qt) 3.5 (3.7, 3.1) 3.5 (3.7, 3.1) 9.8 2 (US qt, Imp qt) 9.3 (9.8, 8.2) (10.4, 8.6) 2 (US qt, Imp qt) 1.2 (1.3, 1.1) 1.4 (1.5, 1.2) 2 (US qt, Imp qt) 0.8 (0.8, 0.7) 2 (US qt, Imp qt) 0.7 (0.7, 0.6) 2 (US qt, Imp qt) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5) 7.3 (7.7, 6.4) 7.2 (7.6, 6.3)
7.2 (7.6, 6.3)
SPC-12
OUTBACK
SPECIFICATIONS
J: WEIGHT
1. US MODEL
OUTBACK 2.5 L Non-turbo 2.5 i 5MT 4AT U5, U6 DC 826 (1,822) 700 (1,544) 1,527 (3,366) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 849 (1,872) 700 (1,544) 1,549 (3,416) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435)
Model
2.5 i BASE 5MT 4AT DC Front kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) 826 (1,822) 696 (1,535) 1,522 (3,357) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 847 (1,867) 696 (1,535) 1,543 (3,402) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435)
2.5 i LTD LLB 4AT EB 863 (1,902) 716 (1,579) 1,579 (3,481) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) EH 863 (1,902) 716 (1,579) 1,579 (3,481) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435)
Destination code OP code
Curb weight (C.W.)
Rear Total
Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.)
Front Rear Total
SPC-13
OUTBACK
SPECIFICATIONS
OUTBACK Model 5MT Destination code OP code Front Curb weight (C.W.) Rear Total Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.) Front Rear Total kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) EB 881 (1,942) 727 (1,604) 1,608 (3,546) 1,040 (2,295) 1,060 (2,340) 2,060 (4,545) 2.5 L Turbo 2.5XT LTD 5AT EB 912 (2,012) 727 (1,604) 1,640 (3,616) 1,040 (2,295) 1,060 (2,340) 2,060 (4,545) U4 EH 915 (2,017) 727 (1,604) 1,642 (3,621) 1,040 (2,295) 1,060 (2,340) 2,060 (4,545) 3.0 L Non-turbo 3.0 R LTD 5AT EB 924 (2,037) 723 (1,594) 1,647 (3,631) 1,040 (2,295) 1,060 (2,340) 2,100 (4,635) EH 926 (2,042) 723 (1,594) 1,649 (3,636) 1,040 (2,295) 1,060 (2,340) 2,100 (4,635)
SPC-14
OUTBACK
SPECIFICATIONS
2. CANADA MODEL
OUTBACK 2.5 L Non-turbo Model 2.5 i BASE 5MT Destination code OP code Front Curb weight (C.W.) Rear Total Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.) Front Rear Total kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) 824 (1,817) 697 (1,537) 1,521 (3,354) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) C0 UC 845 (1,863) 697 (1,537) 1,542 (3,400) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 828 (1,826) 704 (1,552) 1,532 (3,378) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 4AT 5MT C5 DB 848 (1,870) 704 (1,552) 1,552 (3,422) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) 2.5 i 4AT 2.5 i Limited 4AT C0 EB 861 (1,899) 716 (1,579) 1,577 (3,477) 1,040 (2,295) 1,060 (2,340) 2,010 (4,435) EH 926 (2,042) 723 (1,594) 1,649 (3,636) 1,040 (2,295) 1,060 (2,340) 2,100 (4,635) 3.0 L Nonturbo 3.0 R LTD 5AT
Option
SPC-15
OUTBACK
SPECIFICATIONS
SPC-16
Precaution
PRECAUTION
1. Precaution
A: CAUTION
Please clearly understand and adhere to the following general precautions. They must be strictly followed to avoid minor or serious injury to the person doing the work or people in the area.
6. AIRBAG
To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on the airbag components or nearby, around front of the vehicle (radiator panel, front wheel apron, front side frame, bumper, hood, front fender), around side of the vehicle (front door, rear door, center pillar, rear fender, side sill, rear wheel apron), around rear of the vehicle (rear seat cushion, rear floor, rear crossmember) and the airbag wiring harnesses or nearby. To prevent unexpected deployment, turn the ignition switch to OFF and disconnect the ground terminal from battery, then wait at least 20 seconds before starting work.
1. ABS
Handle the ABS as a total system. Do not disassemble or attempt to repair parts which are not instructed in this manual. Follow the directions in this manual when performing maintenance on the ABSCM&H/U. When parts other than those specified are disassembled, it is possible that the ABS system will not operate when needed or cause it to operate incorrectly and result in injury.
2. VEHICLE DYNAMICS CONTROL (VDC)

Handle the VDC as a total system. Do not disassemble or attempt to repair individual parts. Follow the directions in this manual when performing maintenance on the VDCCM&H/U. When parts other than those specified are disassembled, it is possible that the VDC system will not operate when needed or cause it to operate incorrectly and result in injury.
7. AIRBAG AND SEAT BELT PRETENSIONER DISPOSAL

To prevent bodily injury from unexpected airbag deployment, do not dispose the airbag modules and seat belt pretensioner in the same way as other waste. Follow all government regulations concerning disposal of refuse.
8. AIRBAG MODULE
Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment: Do not hold the harnesses or connectors to carry the module. Do not face the bag in the direction that it opens towards yourself or other people. Do not face the bag in the direction that it opens towards the floor or walls.
3. BRAKE FLUID
If brake fluid gets in your eyes or on your skin, do the following: Wash eyes and seek immediate medical attention. Wash your skin with soap and then rinse thoroughly with water.
4. RADIATOR FAN
The radiator fan may rotate without warning, even when the engine is not ON. Do not place your hand, cloth, tools or other items near the fan at any time.
9. AIRBAG SPECIAL TOOL

To prevent unexpected deployment, only use special tools.
5. ROAD TEST
Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic.
10.WINDOW
Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.
11.WINDOW ADHESIVE
Always use the recommended or equivalent adhesive when attaching glass to prevent it from coming falling, resulting in accidents and injury.
PC-2
Precaution
PRECAUTION
12.OIL
When handling oil, carefully observe the following to prevent unexpected accidents. Prepare a container and cloth to prevent scattering of oil when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. Follow all government regulations concerning disposal of refuse when disposing.
13.FUEL
When handling and storing fuel, carefully observe the following to prevent unexpected accidents. Be careful of fires. Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environment. Follow all government and local regulations concerning disposal of refuse when disposing.
14.ENGINE COOLANT
When handling engine coolant, adhere to the following to prevent from unexpected accident. Never remove the radiator cap because of the danger of engine coolant blowing out when the engine coolant is hot. Prepare a container and cloth to prevent spraying of engine coolant when performing work in which engine coolant can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. Follow all government and local regulations concerning disposal of refuse when disposing.
15.AIR CONDITIONER REFRIGERANT

In order to prevent from global warming, avoid releasing air conditioner refrigerant into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.
PC-3
Precaution
PRECAUTION
PC-4
Note
NOTE
1. Note
A: NOTE
This is the information that can improve the efficiency of maintenance and assure the sound work.
7. LIFT AND JACK

When using a lift or shop jack raise a vehicle or using rigid rack to support a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful that the vehicle is balanced before raising it. Be sure to set the wheel stoppers when jacking-up only the front or rear side of the vehicle. NOTE: When using a lift, follow its operation manual before work. Do not work or leave unattended while the vehicle is supported with jack, support it with rigid racks. Be sure to use the rigid racks with rubber attached to cradle to support the vehicle. When using a plate lift, use a rubber attachment.
1. FASTENERS NOTICE
Fasteners are used to prevent the parts from damage, dislocation and play due to looseness. Fasteners must be tightened to the specified torque. Do not apply paint, lubricant, rust retardant or other substance to the surface around bolts, nuts, etc. Doing so will make it difficult to obtain the correct torque and result in looseness and other problem.
2. STATIC ELECTRICITY DAMAGE

Do not touch the control modules, connectors, logic boards and other such parts when there is a possibility of static electricity. Always use a static electricity prevention cord or touch grounded metal for the elimination of static electricity before conducting work.
3. BATTERY
When removing the battery terminal, always be sure to turn the ignition switch to OFF to prevent electrical damage of the control module from overcurrent. Be sure to remove the battery ground cable first.
(A) (C) (B) NT-00070
4. SERVICE PARTS
Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts except for genuine parts.
(A) 80 mm (3.1 in) or more (B) 100 150 mm (3.94 5.91 in) (C) 120 190 mm (4.72 7.48 in)
5. PROTECTING VEHICLE UNDER MAINTENANCE

Make sure to attach the fender cover, seat covers, etc. before work.
Align the cushion rubber end of plate lift with the end of rubber attachment. (Portion b) Also, align the protrusion portion of the supporting locations with the end of attachment. (Portion a)
6. ENSURING SECURITY DURING WORK

When working in a group of two or more, perform the work with calling each other to ensure mutual safety.
NT-2
Note
NOTE
Do not use the plate lift whose attachment does not reach the supporting locations.
(1)
(2)
(3)
(6)
(4)
(6)
(5)
a b
(6)
(6)
a NT-00086
(1) (2)
Supporting locations Pantograph jack
(3) (4)
Swing arm lift Rigid rack
(5) (6)
Plate lift Attachment
NT-3
Note
NOTE
(A)
(1)
(B)
(2)
NT-00170
(A) (1)
Front Front crossmember
(B) (2)
Rear Rear differential
NT-4
Note
NOTE
8. TIE-DOWNS
Tie-downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to the specified locations on the vehicle. TIE-DOWN LOCATION CAUTION: Use the T-hook for rear tie-down. Do not use the hook other than T-hook, otherwise it can be removed when transporting vehicles.
(1)
(1) (1)
NT-00149
(1)
Hook for tie-down
CHAIN DIRECTION AT TIE-DOWN CONDITION NOTE: Pull the chains LH and RH in the same direction, but front and rear side in the counter direction. Pull all the chains in a same moment.
NT-00117
NT-5
Note
NOTE
CHAIN PULLING RANGE AT TIE-DOWN CONDITION

(2) (2) (2) (2) (2) (2)
VEHICLE SINKING VOLUME AT TIE-DOWN CONDITION Measure the distance between the highest tire point and highest arch point before and after tiedown. Difference of measured values (sinking volume) should be within 50 mm (1.97 in) and make sure to fix the vehicle securely.
(3) (3)
(3) (3) : (1) NT-00122
L L
(1) Chain pulling range at tie-down condition (2) 20 (3) 45

NT-00076
(2) (1) F
(2) (1)
NT-00151
(F) Front side (1) Tightening direction of chain (2) 45
NT-6
Note
NOTE
9. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight. Do not tow other vehicles with a front tie-down hook. Make sure the vehicle towing is heavier than the vehicle being towed. Front Remove the fog light cover (except for OUTBACK model) and hook cover, and then install the hook.
(A)
(B)
(B)
(C)
(C)
NT-00171
(A)
Fog light cover (except for OUTBACK model)
(B)
Hook cover
(C)
Hook
Rear
NT-00078
NT-7
Note
NOTE
Notes
Towing Lifting up four wheels (On a trailer) Precautions Towing the vehicle after lifting up all four wheels is a basic rule for AWD model. MT AT
NT-00023
Rope
Check if both front and rear wheels are rotated normally. AT model driving conditions: Driving speed of 50 km/h (31 MPH) or less Allow driving distance 30 km (19 miles) or less
NT-00024
Raising the front wheels
Prohibited for full-time AWD model.
NT-00025
Lifting up the front wheels
Prohibited, due to damage on bumper, front grille, etc. Do not raise the vehicle with bumper.
NT-00026
Marked
: OK, Marked
: Prohibited, Marked
: Conditionally OK.
NT-8
Note
NOTE
CAUTION: Check ATF, gear oil and rear differential oil before driving. Place the shift lever in N position during towing. Do not lift up the rear wheels to avoid unsteady rotation. Turn the ignition key to ACC, then check the steering wheel moves freely. Release the parking brake to avoid tire dragging. Since the power steering does not work, be careful for the heavy steering effort. (When engine is stopped) Since the servo brake does not work, be careful that the brake is not applied effectively. (When engine is stopped) In case of the malfunction of internal transmission or drive system, lift up four wheels (on a trailer) for towing.
10.FRONT HOOD STAY INSTALLATION

At the check and general maintenance
NT-00079
When wider hood opening is necessary Set the stay into the hole of lower hood as shown in the figure below.
NT-00080
NT-9
Note
NOTE
11.GENERAL SCAN TOOL

Using general scan tools will greatly improve the efficiency of repairing engine electronic throttle controls. Subaru Select Monitor can be used to diagnose the engine, VDC, air conditioner and other parts.
13.SPEEDOMETER TEST
1) Rear wheel free roller system (1) Set the free roller on the floor of rear wheel side securely according to the wheel base and rear tread of the vehicle. (2) Let the vehicle ride on the tester and free roller gently. CAUTION: Fix the vehicle using a pulling metal (chain or wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front wheels and springing out of vehicle.
12.AWD CIRCUIT MEASURES

1) Full-time AWD MT model Since viscous coupling (limited slip differential) is used in the center differential, cut-off of AWD circuit cannot be carried out. 2) Full-time AWD 5AT model Since VTD type is used in the center differential, cut-off of AWD circuit cannot be carried out. 3) Full-time AWD 4AT model Insert a spare fuse into FWD fuse holder in the fuse box located in the left side of engine room to select the FWD. Since electronically controlled MT-P hydraulic multi-plate clutch is adapted for center differential, select FWD. When maintenance is performed with jack-up or on the free roller, check the illumination of AWD warning light in the combination meter.
(A) NT-00033
(A) Free roller
(3) Set the speedometer tester. (4) Conduct the speedometer test work. CAUTION: Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work.
(A)
(B)
NT-00081
(A) FWD fuse holder (B) AWD warning light
NT-10
Note
NOTE
2) Rear wheel jack-up system (1) Set the vehicle on speedometer tester. CAUTION: Fix the vehicle using a pulling metal (chain or wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front wheels and springing out of vehicle. (2) Jack up the rear wheels and set the rigid racks to the specified locations of side sill.
14.BRAKE TEST
1) Full-time AWD MT model (1) Perform this test after driving the vehicle 2 to 3 km (1.24 to 1.86 miles) on road in order to stabilize the viscous torque of viscous coupling. (2) Keep the front or rear wheels on the ground for this test. NOTE: Effect of the viscous torque on braking force will be added approx. 25 kg compared with FWD model.
(A) NT-00034
(C)
(A)
(B) NT-00029
(A) Rigid rack
(3) Conduct the speedometer test work. CAUTION: Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work.
(A) Brake tester (B) Position for measuring front wheel (C) Position for measuring rear wheel
(3) When the brake dragging force is large. Check the dragging of brake pad or brake shoe. Since it may be affected by the viscosity of viscous coupling, jack up either of the front or rear two wheels to check the each wheel rotation condition with the viscous coupling affection removed.
NT-11
Note
NOTE
2) Full-time AWD AT model (1) Keep the front or rear wheels on the ground during measurement.
15.ON THE CAR WHEEL BALANCING

CAUTION: Carry out this procedures after measuring the balance of each single tire. Set the vehicle so that the front and rear wheels are the same height. Release the parking brake during measurement. Rotate each wheel by hands, and make sure it rotates without dragging. Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work. When an error is indicated during engine drive, do not use the motor drive together. 1) Set the rigid rack to the specified locations of side sill, jack up the front or rear two wheels of nonmeasuring side and set the pickup stands to two wheels of measuring side.
(C)
(A)
(B) NT-00029
(A) Brake tester (B) Position for measuring front wheel (C) Position for measuring rear wheel
(2) When the brake dragging force is large. Check the dragging of brake pad or brake shoe. Specifications:
Rear wheel total Difference between right and left wheels Grand total Braking force 10% or more of load on front or rear wheels 8% or less of load on front or rear wheels 50% or more of vehicle weight at the time of test
(A)
(B)
NT-00031
(A) Balancer body (B) Pickup stand
When measurement is difficult to carry out because both of front wheels are locked, brake force measurement in this condition conforms to standard grand total.
2) For drive wheel, drive the tires with engine for measurement. 3) For non-drive wheel, drive the tires from the on the car wheel balancer for measurement.
NT-12
Identification
IDENTIFICATION
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER & LABEL LOCATIONS
The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION
(1)
(2)
(4)
(5) (3)
(2)
ID-00167
(1) (2)
Emission control label Vehicle identification number (V.I.N.)
(3) (4)
Model number label (Right side) Tire inflation pressure label (Drivers side)
(5)
Emission control label FMVSS label (U.S. model) (Left side) CMVSS label (Canada model) (Left side)
ID-2
Identification
IDENTIFICATION
ENGINE
(1)
MANUAL TRANSMISSION 5MT (non-turbo model)
(1)
(2) ID-00059 ID-00279
(1) Engine serial number (Punch mark) (2) Engine type (Crankcase upper side)
(1) MT type and Transmission serial number label
AUTOMATIC TRANSMISSION 4AT
5MT (turbo model)
(1) (1)
ID-00263 ID-00262
(1) MT type and Transmission serial number label
(1) AT type and Transmission serial number label
6MT
(2)
5AT
(1) (2)
(1)
ID-00137
ID-00067
(1) AT type label (2) Transmission serial number label
(1) Transmission serial No. (2) MT type label
ID-3
Identification
IDENTIFICATION
REAR DIFFERENTIAL T-TYPE

(1)
VA2-TYPE
(1)
DI-00397 ID-00257
(1) Type (label) (1) Type (white paint)
VA1-TYPE
(1)
DI-00396
(1) Type (label)
MODEL NUMBER LABEL
ID-00280
ID-4
Identification
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the V.I.N. is as follows: ]4S3BL616X96210001[ The starting and ending brackets ( ] [ ) are stop marks.
Digits 13 4 5 6 7 Code 4S3 B L 6 1 Meaning Manufacturer body area Car line Body type Displacement Grade Details 4S3: For C0 except OUTBACK model 4S4: For C0 OUTBACK model B: LEGACY L: Sedan P: Wagon 6: 2.5 L AWD 8: 3.0 L AWD 0: 2.5 i BASE, OUTBACK 2.5 i BASE 1: 2.5 i, OUTBACK 2.5 i 2: 2.5 i-LTD, OUTBACK 2.5 i-LTD 3: OUTBACK 2.5 XT-LTD 4: 3.0 R 5: OUTBACK 3.0 R-LTD, 3.0 R-LTD 6: OUTBACK 2.5 i-LTD-LLB (L.L.Bean) 7: 2.5 GT-LTD 9: 2.5 GT-B 6: Manual belts, Dual airbag, Side airbag (Except for OUTBACK model) C: Class C (GVWR 4001 5000 lb) (OUTBACK model) 0 9&X 9: 2009MY 3: Full-time AWD 6MT 4: Full-time AWD 5AT 6: Full-time AWD 5MT 7: Full-time AWD 4AT From 210001: Sedan From 310001: Wagon
Restraint system or GVWR Class Check digit Model year Transmission type
9 10 11
X 9 6
12 17
210001
Serial number
ID-5
Identification
IDENTIFICATION
3. MODEL NUMBER PLATE

The model number plate indicates the type, V.I.N. <Ref. to ID-5, MEANING OF V.I.N., IDENTIFICATION, Identification.>, applied model, option code, trim code, engine type, transmission type and the exterior color code. This information is helpful when placing orders for parts. BL9FYJJ
Digits 1 2 3 B L 9 Code Meaning Series Body type Engine displacement Drive system Suspension system Model year Destination Grade Details LEGACY L: Sedan P: Wagon 9: 2.5 L AWD E: 3.0 L AWD F: 2009MY Y: U.S., Canada C: 2.5 GT Limited D: OUTBACK 2.5 XT Limited F: 2.5 GT spec. B H: 2.5 i J: 2.5 i BASE K: 2.5 i Limited L: 3.0 R Limited N: 3.0 R P: OUTBACK 2.5 BASE S: OUTBACK 2.5 i T: OUTBACK 2.5 i Limited U: OUTBACK 3.0 R V: OUTBACK 3.0 R Limited W: OUTBACK 2.5 i LTD-LLB D: DOHC MFI Turbo 5MT J: SOHC MFI 5MT H: DOHC MFI Turbo 6MT L: SOHC MFI 4AT TIP U: DOHC MFI 5AT TIP V: DOHC MFI Turbo 5AT TIP
4 5 6
F Y J
Transmission, fuel feed system
The engine and transmission type are as follows. ENGINE EJ253CSFFB

Digits 1 and 2 3 and 4 5 Code EJ 25 3 Meaning Engine type Displacement Fuel feed system Details EJ: 4 cylinder EZ: 6 cylinders 25: 2.5 L 30: 3.0 L 3: MFI Non-turbo (SOHC) 5: MFI turbo D: MFI Non-turbo (DOHC, H6) A: For states not using California emission standards B: For USA C: For states using California emission standards C: D-5AT E: 5MT (Flexible type flywheel, Wide angle damper type disc wheel) F: 6MT (Flywheel 230) P: 4AT S: 5MT (Flexible type flywheel) Used when ordering parts. For details, refer to the parts catalog.
Emission control
Mounted transmission
8 10
FFB
Detailed specifications
ID-6
Identification
IDENTIFICATION
Transmission 1. MT TY758VCAAA
Digits 1 2 3 and 4 5 6 Code T Y 75 8 V Meaning Transmission Transmission type Identification Series Transmission specifications Details T: Transmission Y: Full-time AWD MT center differential 75: 5MT 85: 6MT 6: 6MT 8: 5MT V: Full-time AWD 5MT single range with viscous coupling center differential W: Full-time AWD 6MT single range with viscous coupling center differential C: 2.5 L SOHC W: 2.5 L DOHC Turbo Used when ordering parts. For details, refer to the parts catalog.
7 8 10
C AAA
Mounted vehicle Detailed specifications
2. AT TZ1B8LCEBA
Digits 1 2 3 and 4 5 6 7 T Z 1B 8 L C Code Meaning Transmission Transmission type Identification Series Transmission specifications Mounted vehicle Details T: Transmission G: Full-time AWD 5AT center differential Z: Full-time AWD 4AT MPT 1B: 4AT 5D: 5AT 7: 5AT 8: 4AT C: Full-time AWD VTD 5AT L: Full-time AWD MPT 4AT C: 2.5 L SOHC Sedan, Touring wagon F: 2.5 L SOHC OUTBACK V: 3.0 L DOHC W: 2.5 L DOHC Turbo Used when ordering parts. For details, refer to the parts catalog.
8 10
EBA
Detailed specifications
REAR DIFFERENTIAL
Code CD CF EW HY JE T1 T2 TP XJ XT XU XZ 4.444 4.444 3.900 3.545 4.111 3.900 4.111 4.444 4.111 3.083 3.272 3.083 Reduction gear ratio Viscous Viscous Viscous Torsen Viscous None None None None Viscous Viscous Viscous LSD
ID-7
Identification
IDENTIFICATION
OPTION U5DC
Digits 12 Code U5 Meaning Destination Details C0: Canada U4: U.S. For USA U5: U.S. For states using California emission standards U6: U.S. For states not using California emission standards 3: Cruise control, Power pack D: Vehicle dynamics control (VDC), Cruise control E: Vehicle dynamics control (VDC), Cruise control, Power pack U: Cruise control B: None C: A/C, Side airbag, Curtain airbag H: A/C, Side airbag, Curtain airbag, Sunroof, Navigation system, Dark colored glass K: A/C, Side airbag, Curtain airbag, Sunroof, Navigation system W: A/C, Side airbag, Curtain airbag, Sunroof
Option equipment
Option equipment
ID-8
Recommended Materials
RECOMMENDED MATERIALS
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality.
2. FUEL
Always use gasoline of the same or higher octane value than specified in the owners manual. Ignoring the specifications below will result in damage or poor performance of engine and fuel injection system. Use the specified gasoline to correct performance. Unleaded gasoline In order to reduce air pollution, use unleaded gasoline for the vehicle equipped with catalytic converter. Using leaded gasoline may damage the catalytic converter.
3. LUBRICANTS
Use the lubricants shown in the table below, or equivalent. See the table below to choose the correct SAE viscosity.
Lubricants Engine oil Choose oil suitable for the standard from the right. Recommended materials API standard SM Energy conserving ILSAC standard GF-4
TR OLEUM
SERVICE S PI
PE
AM ER I CA
IN
VI
NG
SAE 5W-30
GY
FOR GASOLINE ENGINES

ER
T I F IE

ST I
TUTE
EN
CONS E
D
RM-00002
RM-00049
Manual transmission oil AT front differential gear oil Rear differential gear oil
GL-5 GL-5 GL-5
RM-2
SAE viscosity No. and applicable temperature Engine oil
(C) 30 20 10 0 10 20 30 40
(F)
22
14
32
50
68
86
104
10W-30 or 10W-40
5W-30 Recommend
RM-00060
Manual transmission oil, rear differential gear oil and AT front differential gear oil
(C) 30 20 10 0 10 20 30 40
(F)
22
14
32
50
68
86
104
90
85W
80W
75W-90
RM-00004
RM-3
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid. CAUTION: Always use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble.
Fluid Automatic transmission fluid Power steering fluid Brake fluid Clutch fluid Recommended materials SUBARU ATF HP DEXRON III FMVSS No. 116, DOT3, or DOT4 FMVSS No. 116, DOT3, or DOT4 Alternative IDEMITSU: ATF HP Remarks
5. COOLANT
Use the genuine coolants to protect the engine.
Engine coolant Coolant Recommended materials SUBARU SUPER COOLANT (Concentrated type) SUBARU SUPER COOLANT (Diluted type) Distilled water Cooling system conditioner Item number K0670Y0000 SOA345001 Soft water or tap water Alternative
Water for dilution Cooling system protective agent
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any compressor oil other than DENSO OIL 8.
Air conditioner Refrigerant Compressor oil Recommended materials HFC134a DENSO OIL 8 Item number Alternative None None
RM-4
7. GREASE
Use grease and supplementary lubricants shown in the table below.
Grease Supplementary lubricants Grease Application point Oxygen sensor MT main shaft Clutch master cylinder push rod Gear shift lever Clutch activating cylinder Clutch pedal Brake pedal Clutch bearing Clutch release lever Select lever Steering gearbox Disc brake (lock pin, guide pin, piston boot) Between brake pad and shim Brake pad clip Front axle PTJ Front axle EBJ Rear axle EBJ Rear axle BJ Rear axle DOJ Recommended materials Spray type lubricant NICHIMOLY N-130 SILICONE GREASE G-40M Item number 004404003 Alternative
SUNLIGHT 2
003602010
VALIANT GREASE M2 NIGLUBE RX-2 Molykote AS-880N Molykote M7439 NKG302 NTG2218-M NKG106 NKG205
003608001 000041000 K0777YA010 K0777YA000
ONE LUBER SG or MO
8. ADHESIVE
Use the adhesives shown in the table below, or equivalent.
Adhesive Adhesive Application point Windshield, rear window glass, rear quarter glass, rear gate and body Recommended materials Dow Automotives adhesive: ESSEX U-400HV or the equivalent Glass primer: U-401 and U-402 Painted surface primer: U-413 REPAIR KIT IN MR Item number Alternative
Rearview mirror base
65029FC000
RM-5
9. SEAL MATERIAL
Use the seal material shown in the table below, or equivalent.
Seal material Seal material Application point MT transmission case Converter case Cylinder block Camshaft cap Cylinder head plug (Turbo model) Oil pump (Except for 3.0 L model) Cylinder head plug (Turbo model) Rocker cover (3.0 L model and turbo model) Engine oil pan (Pan upper) (3.0 L model) Block (Pan upper) (3.0 L model) Back cover (Front cover, block, head, pan upper) (3.0 L model) Engine oil pan (Except for 3.0 L model) Separator cover (Except for 3.0 L model) Transmission oil pan (AT model) Rear differential (Side retainer bolt) Rear differential Engine oil pressure switch Connector (Oil hose) (Turbo model) Connector (Heater hose) (3.0 L model) Cylinder head (Nipple) (3.0 L model) Camshaft bowl-shape plug (3.0 L model) Rear differential Service hole plug (Except for 3.0 L model) Steering adjusting screw PCV Valve Door (Front sealing cover) Door (Rear sealing cover) Recommended materials THREE BOND 1215 Item number 004403007 Alternative DOW CORNING No. 7038
THREE BOND 1217G
K0877Y0100
THREE BOND 1217B THREE BOND 1110B
K0877YA020 K0879Y0020
Seal material
THREE BOND 1324
004403042
THREE BOND 1105
004403010
DOW CORNING No. 7038
THREE BOND 1141
004403006
3M Butyl Rubber 8626
RM-6
Pre-delivery Inspection
PRE-DELIVERY INSPECTION
1. Pre-delivery Inspection
A: GENERAL DESCRIPTION
The purposes of the pre-delivery inspection (PDI) are as follows. Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal condition. Check the vehicle before delivery is in normal condition. Check the vehicle or parts for any damage occurred during transportation or storage. Check the vehicle after repair is in normal condition. Make sure to provide a complete vehicle to customer. For above reasons, all SUBARU dealers (dealerships) must carry out the PDIs before delivery of vehicle. Refer to this manual unless otherwise specified.
PI-2
B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE

STATIC CHECKS JUST AFTER VEHICLE RECEIPT
Procedure 1. Appearance check Check point 1. If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. If the protective coating has been removed, visually check the body painted area for damage or stains in detail. 2. Visually check the glass and light lenses for any damage, cracks or excessive gaps between body sheet metal. 3. Visually check the plated parts for any damage. 1. Check the tires for damage, defective, and dents on wheels. 2. Check the tire air pressure. If the vehicle is about to be delivered to customer, attach a back-up fuse. 1. Using the key, check the trunk lid can be locked or unlocked normally. 2. Open and close all doors to check that there are no defective. 3. Operate the power door lock switch to check that the door (rear gate) is locked and unlocked normally. Check the child safety lock system operates normally. 1. Operate the trunk lock release lever to check that the trunk lid opens normally. 2. Check that main and sub keys can lock/unlock the release lever, and that valet key can not lock/unlock the release lever. 3. Open and close the trunk lid to see that there are no abnormal conditions. Operate the trunk lid release lever to check that the trunk lock is unlocked normally. 1. Check if the rear gate can be unlocked normally through the emergency hole. 2. Open and close the rear gate to see that there are no abnormal conditions. Operate the fuel lid opener to check that the fuel filler lid can be unlocked normally. Check that the following accessories are provided. Owners manual Warranty booklet Maintenance note Spare key Jack Tool set Spare tire Operate the front hood lock release lever to check that the front hood is unlocked normally. Check the battery terminals for any abnormal conditions such as rust and trace of battery fluid leaks. Check that the fluid level is normal. Check that the oil level is normal. Check that the transmission gear oil level is normal. Check that the AT front differential oil level is normal. Check that the engine coolant level is normal. Check that the clutch fluid level is normal. Check that the window washer fluid level is normal. Check that the hood is closed and latched securely. Check that the keyless entry system operates normally. Check that the alarm system (anti-theft alarm) operates normally. 1. Check the seat surfaces for stains or dirt. 2. Check the seat installation conditions and functionality. 3. Check that the occupant detection system for passengers seat operates normally. 1. Check the seat belt installation conditions and functionality. 2. Check that the seat belt warning system operates normally.
2. Tire check 3. Fuse installation 4. Lock/unlock and open/close operation checks of doors
5. Child safety lock system 6. Open/close operations checks of trunk lid
7. Operation check of trunk lid release lever 8. Rear gate lock/unlock and open/close 9. Fuel lid opener lock release lever 10. Accessory check
11. Front hood lock release system 12. Battery 13. Brake fluid 14. Engine oil 15. Transmission gear oil 16. AT front differential gear oil 17. Engine coolant 18. Clutch fluid 19. Window washer fluid 20. Front hood latch 21. Keyless entry system 22. Alarm system (Anti-theft alarm) 23. Seat
24. Seat belt
PI-3
CHECKS WITH THE ENGINE RUNNING

Procedure 25. Delivery (test) mode connector 26. Immobilizer system Check point Turn the ignition switch to ON and check that the malfunction indicator light starts blinking. 1. Check that the engine starts with all keys that are equipped on vehicle. 2. 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light blinking. Start the engine and check that the engine starts smoothly. Check that the exhaust noise is normal and no leaks are found. Check that all indicator lights and warning lights operate normally. Check that the heater & ventilation system operates normally. Check that the air conditioner operates normally. Check that the clock operates normally. Check the radio and CD player for normal operation. 1. Check all display functions for normal operation. 2. Check the map disc (DVD) are provided on vehicle. 3. Check that the navigation system operates normally. Check that the front accessory power supply socket operates normally. Check that the lighting system operates normally. Check that the wiper deicer operates normally. Check that the illumination control operates normally. Check that the window washer system operates normally. Check that the wiper system operates normally. Check the power window for normal operations. Check that the sunroof operates normally. Check that the remote control mirror operates normally.
27. Starting condition 28. Exhaust system 29. Indicator and warning lights 30. Heater & ventilation 31. Air conditioner 32. Clock 33. Audio 34. Navigation system
35. Front accessory power supply socket 36. Lighting system 37. Wiper deicer 38. Illumination control 39. Window washer 40. Wiper 41. Power window 42. Sunroof 43. Door mirror
DYNAMIC TEST WITH THE VEHICLE RUNNING

Procedure 44. Brake test 45. Parking brake 46. AT shift control 47. Cruise control Check point Check the foot brake for normal operations. Check the parking brake for normal operations. Check that the AT shift patterns are correct. Check that the cruise control system operates normally.
CHECKS AFTER DYNAMIC TEST

Procedure 48. ATF level 49. Power steering fluid level 50. Fluid leakage 51. Water leak test 52. Appearance check 2 Check point Check that the ATF level is correct. Check that the power steering fluid level is normal. Check for fluid/oil leaks. Spray the vehicle with water and check for water leaks. 1. Remove the protective coating (if equipped). 2. Check the body paints for damage and stain. 3. Check the plated parts for damage and rust.
PI-4
1. APPEARANCE CHECK
If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. When the protective coating is removed, visually check the body paints for damage or stains in detail and repair as necessary. Visually check the windshield glass, door glasses and light lenses for any damage, cracks or excessive gaps to the body sheet metal and repair as necessary. Visually check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and replace the parts as necessary.
4. LOCK/UNLOCK AND OPEN/CLOSE OPERATION CHECKS OF DOORS

1) Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.
(A) (B)
2. TIRE CHECK
Check the tires for damage, defective, and dents on wheels. Check and adjust the tire size, spare tire and tire air pressure described on the tire air pressure label (drivers side).
(A) Unlock (B) Lock
PI-00246
3. FUSE INSTALLATION
Fuses for the back-up circuit have been removed to prevent battery discharge. If the vehicle is about to be delivered to the customer, attach a 20 A fuse (A) as shown in the figure.
2) Completely close the drivers door, and then check the smooth movement with operating door lock knob from lock to unlock several times. Set the door lock knob (A) to lock position. Then pull the inner remote (B) to ensure that doors will not open. For other doors, place the door lock knob (A) to lock position and then pull the inner remote (B) to ensure that doors will not open.
(A)
(A) (B) PI-00158 PI-00192
(A) Door lock knob (B) Inner remote
3) Close all the doors, and then press the lock on power door lock switch at drivers side. Check that all doors including rear gate are locked.
PI-00392
PI-5
4) Press the drivers side power door lock switch to unlock side. Check that all doors including rear gate are unlocked.
5. OPERATION CHECK OF CHILD SAFETY LOCK SYSTEM

1) Set the child safety lock on both rear doors to the lock position. 2) Close the rear doors completely. 3) Check that the lock levers of the rear doors are in the unlock position. Then, pull inner remote of rear doors to ensure that the doors will not open.
(A) (B)
PI-00393
5) Check that the power door lock switch on the passengers side also locks and unlocks.
PI-00164
(A)
(A) Lock (B) Unlock
(B) PI-00247
4) Pull the outer handles to ensure that doors will open.
6. OPEN/CLOSE OPERATION CHECKS OF TRUNK LID

1) Operate the trunk lock release lever to check that the trunk lid opens normally. 2) Open and close the trunk lid several times for smooth movement. 3) Lock the trunk lock release lever using main key or sub key.
(A) Lock (B) Unlock
6) Insert the key to ignition switch, and open the drivers side door. Press lock on power door lock. Check that the door is not locked.
PI-00258
4) Check that the trunk lock release lever does not operate. 5) Check if the trunk lock release lever is not locked and unlocked using valet key.
PI-6
7. OPERATION CHECK OF TRUNK LID RELEASE HANDLE

1) Use a flat tip screwdriver. Slide the screwdriver blade from the slit aperture of the lock assembly fully to the end until you hear a click. This places the latch in the locked position.
8. LOCK/UNLOCK AND OPEN/CLOSE OPERATION CHECKS OF REAR GATE

1) Open and close the rear gate several times for smooth movement. 2) Operate the rear gate lever to check that the rear gate is locked and unlocked normally. (1) Remove the cover inside the rear gate.
PI-00248
2) Move the release handle from outside the vehicle in the direction of the arrow to check if the latch is released.
PI-00165
(2) Operate the lever to check that the rear gate is locked and unlocked normally.
PI-00249
PI-00166
9. OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER

Operate the fuel lid opener to check that the fuel filler lid can be unlocked normally. Check that the filler cap is securely closed.
PI-7
10.ACCESSORY CHECK
Check that the following accessories are provided. Owners manual Warranty booklet Maintenance note Spare key Jack Tool set Spare tire
(B) (A)
11.OPERATION CHECK OF FRONT HOOD LOCK RELEASE SYSTEM

Operate the front hood lock release lever (A) to check that the front hood is unlocked normally.
(A)
PI-00195
Operate the lever (B) and check that the front hood is opened normally. Support the front hood with hood stay.
PI-00168
(B)
(A) PI-00169
(A) Jack (B) Jack handle
(B) PI-00381
PI-8
12.BATTERY
Check the battery terminals to make sure that there are no rust or corrosions due to fluid leaks.
14.ENGINE OIL
Check the engine oil amount. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil. Except for 3.0 L model
(A) (B) (F)
(C) (E) PI-00250 (D)
13.BRAKE FLUID
Check that the brake fluid level is normal. If the amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid.
PM-00362
(A)
(A) (B) (C) (D) (E) (F)
Oil level gauge Engine oil filler cap Upper level Lower level Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) Notch mark
3.0 L model
X MA MI N
(B) (A)
(B)
F
(C) (E)
PI-00251
(D)
(A) MAX. level (B) MIN. level
PM-00363
(A) (B) (C) (D) (E)
Oil level gauge Engine oil filler cap Upper level Lower level Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
PI-9
15.TRANSMISSION GEAR OIL

Check that the transmission gear oil level is normal. If the amount of fluid is insufficient, check that no leaks are found. Then add the necessary amount of the specified transmission gear oil. 5MT model (Non-turbo model)
(A)
16.AT FRONT DIFFERENTIAL GEAR OIL

Check that the AT front differential oil level is normal. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil. 4AT model
(A) (B) (C) (B) (C) (A)
PM-00030
AT-04840
(A) Oil level gauge (B) Upper level (C) Lower level
5MT model (Turbo model)

(A)
5AT model
(A) (A)
F (C) L (B) PI-00391
(B) (C)
PI-00184
6MT model
(A)
(A)
(B) (C)
MT-00449
PI-10
17.ENGINE COOLANT
Check that the engine coolant level on the reservoir tank is normal. If the amount of engine coolant is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration.
21.KEYLESS ENTRY SYSTEM

NOTE: The following inspections show the initial settings. When the settings are different from the initial settings, use Subaru Select Monitor to check the details of each setting for inspections. <Ref. to LAN(diag)-29, OPERATION, Read Current Data.> 1) Fully open all the door windows. 2) Remove the key from the ignition switch and close all the doors including rear gate. 3) Press the rear gate and trunk open button for at least one second. Check if the trunk is opened and the hazard light blinks twice and the buzzer sounds twice. (Sedan model) Check if the rear gate is unlocked and the hazard light blinks twice and the buzzer sounds twice. (Wagon model)
18.CLUTCH FLUID
Check that the clutch fluid level is normal. If the amount of fluid is insufficient, check that no leaks are found. Then, add the necessary amount of specified fluid.
(A) (C)
X
MA N MI
(B) PI-00253
(A) Reservoir tank (B) MIN. level (C) MAX. level
19.WINDOW WASHER FLUID

Check that the window washer fluid level is normal. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid.
PI-00388
20.FRONT HOOD LATCH

Retract the front hood stay and close the front hood. Check that the front hood is securely latched.
4) Press the LOCK button on the keyless transmitter with one of the doors (including the rear gate and trunk) opened. Check if all doors are locked, hazard light blinks five times and the buzzer sounds five times and warning shows one of the doors (including the rear gate and trunk) open. 5) Close all the doors including rear gate and trunk. Press the LOCK button momentarily on the keyless transmitter. Check that all the doors (including rear gate and trunk) are locked, hazard light blinks once and buzzer sounds once.
PI-00387
PI-11
6) Press the UNLOCK button momentarily on the keyless transmitter. Check that the drivers door is unlocked and hazard light blinks twice and the buzzer sounds twice. And press the UNLOCK button momentarily again in 5 seconds. Check that all doors (including rear gate) are unlocked.
10) Press the Panic button of the keyless transmitter. Check if the alarm condition happens (horn sounds continuously, hazard light blinks, security indicator comes on). Check whether this condition lasts until any button on the keyless transmitter is pressed or lasts for 30 seconds.
PI-00389 PI-00388
7) Within a distance of 10 m (33 ft) from a vehicle, press keyless transmitters LOCK button three times within 5 seconds. Check that the horn honks once and that the hazard light blinks three times. 8) Move the power door lock switch to the lock position with one of doors (including the rear gate) opened. Next, close all the doors including rear gate. Check if all doors are locked and buzzer sounds once and the hazard light flashes once. 9) Check buzzer operation. The buzzer sounds when the doors are locked or unlocked. The buzzer can be turned off if desired. Turn the buzzer off or on with following procedure. (1) Close all the doors including rear gate, then remove the key from ignition key lock. (2) Press the power door lock switch to unlock and hold it until the operation is finished. (3) Insert the key into ignition key lock, and insert and remove the key in ignition key lock 5 times in 10 seconds. (4) When finished step (3), open and close the drivers door once within 10 seconds. NOTE: When opening and closing of the door is not available within 10 seconds, hazard light blinks once and the change over operation is cancelled. Retry from the step (1). (5) Hazard light blinks 3 times and the buzzer sound turns ON or OFF.
PI-12
22.ALARM SYSTEM
NOTE: The following inspections show the initial settings. When the settings are different from the initial settings, use Subaru Select Monitor to check the details of each setting for inspections. <Ref. to LAN(diag)-30, OPERATION, Function Setting (Customize).> 1) Fully open all the door windows. 2) Remove the key from the ignition switch and close all the doors including rear gate. 3) Press the LOCK button momentarily on the keyless transmitter. All doors are locked, and buzzer sounds once, hazard blinks once, security indicator light blinks faster (five times per two seconds) for 30 seconds and goes slower (twice per two seconds), then the alarm system is in set condition.
6) Unlock a door using the inner lock knob and open the door while the security system is in the set mode. Check if the alarm condition happens (horn sounds continuously, hazard light blinks, security indicator illuminates). Check if this condition lasts for a maximum of three minutes or until the UNLOCK button of the keyless transmitter is pressed. NOTE: The alarm condition will cease in 30 seconds once the door is closed. 7) When none of above is applicable, check the troubleshooting of security system.
PI-00387
4) Press the UNLOCK button momentarily on the keyless transmitter. When the door of the drivers seat is unlocked, the buzzer sounds twice, the hazard light flashes twice, the room light turns on and the security indicator light flashes once in three seconds, and the alarm system enters the release mode.
PI-00388
5) Close all the doors including rear gate. Press the LOCK button momentarily on the keyless transmitter. When all the doors are locked, buzzer sounds once, hazard blinks once and the alarm system is in set condition in 30 seconds.
PI-13
23.SEAT
1) Check the seat surfaces for stains or dirt. 2) Check that each seat provides full functionality in sliding and reclining. Check that the seat position memory for drivers power seat function properly. Check all available functions of the rear seat such as a trunk-through center armrest. 3) Check that the passengers seat occupant detection system. (1) Turn the ignition switch to ON. (2) Check that the ON and OFF of passengers airbag indicator light come on simultaneously for about 6 seconds and go off for 2 seconds, and then only OFF illuminates again.
25.DELIVERY (TEST) MODE CONNECTOR

Turn the ignition switch to ON and check that the malfunction indicator light starts blinking. If the light blinks, return the ignition key to LOCK. Pull out the test mode connector from the back of glove box lower cover, and disconnect the test mode connector. Then, turn the ignition key to ON again. If the malfunction indicator light blinks at that time in spite of the disconnected delivery test mode connector, carry out an engine diagnosis.
(A)
PI-00201
(A) Delivery (test) mode connector

OD-00036
26.IMMOBILIZER SYSTEM
1) Check that the engine starts with all keys that are equipped on vehicle. 2) 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light blinking. NOTE: If malfunctions occur, refer to IMMOBILIZER (DIAGNOSIS).
(3) Have a person weighing approximately 70 kg (155 lb) or more sit in the passengers seat, and check whether the passengers airbag indicator light illuminate or not. (4) Empty the passenger seat, then check whether the passenger side airbag indicator light OFF illuminates.
24.SEAT BELT
1) Check installation condition of seat belt. 2) Pull out the seat belt and then release it. Check that the belt retracts smoothly. 3) Check that the ALR seat belt operates normally. 4) Check seat belt warning system (1) Turn the ignition switch to ON without fastening drivers and passengers seat belts. (2) Check if the seat belt warning lights of drivers and passengers side blink for about six seconds and the buzzer beeps intermittently. (3) Then, check that the seat belt warning light comes on o blink in about 15 second cycles. (If the passenger seat is empty, the seat belt warning light for passengers side does not operate.)
27.STARTING CONDITION
Start the engine and check that the engine starts smoothly. If the battery voltage is low, recharge or replace the battery. If any noises are observed, immediately stop the engine and check and repair the abnormal components.
28.EXHAUST SYSTEM
Listen to the exhaust noise to see if no noises are observed. Check for exhaust leaks.
29.INDICATOR AND WARNING LIGHTS

Check that all indicator lights and warning lights operate normally.
30.HEATER & VENTILATION

Operate the heater & ventilation system to check for normal airflow outlet control, air inlet control, airflow capacity and heating performance.
PI-14
31.AIR CONDITIONER
Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided. NOTE: To prevent the insufficient lubrication of air conditioner, operate the air conditioner for 5 minutes at idling.
39.WINDOW WASHER
Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure. Front injection position: A: 250 mm (9.84 in) B: 535 mm (21.1 in)
A A (2)
32.CLOCK
Check the clock for normal operations and enough accuracy.
33.AUDIO
Check the radio for full functionality and normal noise level. Check the CD unit operations.
34.NAVIGATION SYSTEM
1) Check all display functions for normal operation. 2) Check the map disc (DVD) are provided on vehicle. 3) Check that the navigation system operates normally.
(1)
WW-00395
(1) Nozzle (2) Spray area (shaded area)
35.FRONT ACCESSORY POWER SUPPLY SOCKET

1) Check the operation of the front accessory power supply socket. 2) Check operation of the accessory power supply socket in console box.
Rear injection position: Wagon model A: 70 mm (2.8 in) B: 70
36.LIGHTING SYSTEM
1) Check the headlight operations. 2) Check the stop light operation. 3) Check other lights for normal operations.
B
37.WIPER DEICER
Check that the wiper deicer operates normally.
PI-00104
40.WIPER
Check the front and rear wipers for normal operations.
38.ILLUMINATION CONTROL
Check that the illumination control operates normally.
41.POWER WINDOW
Operate the power window switches one by one to check that each of the power windows goes up and down without noises.
42.SUNROOF
Check that the sunroof operates normally.
43.DOOR MIRROR
Check that the remote control mirror operates normally.
44.BRAKE TEST
Check the foot brake for normal operations.
PI-15
45.PARKING BRAKE
Check the parking brake for normal operations. When pulling the parking brake lever with force of 200 N (20.4 kgf, 45.0 lb), check that the lever stroke of parking brake lever is 5 to 6 notches.
48.ATF LEVEL
After selecting all positions (P, R, N, D), set the select lever in P range. Idle the engine for 1 or 2 minutes, and measure the ATF level. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified ATF. 4AT
(A)
46.AT SHIFT CONTROL

1) Turn the ignition switch to ON. 2) While brake pedal is not depressed, check if the select lever does not move from P range. 3) While brake pedal is depressed, check if the select lever moves from P range. 4) Set the select lever to other than P range. 5) When the ignition switch is turned to OFF, check if the ignition key switch cannot be removed. 6) Set the AT selector lever to each gear position and check the shifting while driving the vehicle.
(C) (D)
L F HOT
(B)
(E)
COLD L
(C) (D)
PI-00521
P R N D
(A) Level gauge (B) ATF level range at HOT [70 80C (158 176F)] (C) Upper level (D) Lower level (E) ATF level range at COLD [20 30C (68 86F)]
PI-00199
5AT
F HOT
4AT
(A)
Selector position D Manual mode
1st OK OK
Gear position 2nd 3rd OK OK OK OK
(B) (A)
4th OK OK
(C) (D)
(C)
COLD L
5AT
Selector position D Manual mode 1st OK OK Gear position 2nd 3rd 4th OK OK OK OK OK OK 5th OK OK
(D)
(E)
PI-00362
47.CRUISE CONTROL
Operate the cruise control system. Check that the system is activated and deactivated correctly.
(A) Level gauge (B) ATF level range at HOT [70 80C (158 176F)] (C) Upper level (D) Lower level (E) ATF level range at COLD [20 30C (68 86F)]
PI-16
49.POWER STEERING FLUID LEVEL

Check that the power steering fluid level is normal. If the amount is insufficient, check that no leaks are found. Then add the necessary amount of the specified power steering fluid.
52.APPEARANCE CHECK 2
1) When vehicle body is covered with protective film, peel it off. NOTE: Use of steam facilitates peeling off the wrap guard. For a vehicle left for a long time or at low temperature, sprinkle some water heated to 50 60C (122 140F) over the vehicle to raise its surface temperature before peeling off the wrap guard. Do not use the water heated to over 60C (140F). If the adhesive remains exist on the coated surface, soak a flannel rag, etc. with a small amount of coating wax or solvent such as oil benzene and IPA, put the soaked cloth on the remains lightly, and then wipe them off with a flannel rag etc. Keep solvent from touching the resin or rubber parts. Do not use coating wax or solvent while the component surface temperature is high due to hot weather etc. If the coated surface is swollen out due to seams or moisture, expose the vehicle to the sunlight for a few hours or heat the seam and swollen portions using a dryer etc. Dispose of the peeled wrap guard as burnable industrial garbage. 2) Check the whole vehicle body for flaking paint, damage by transportation, corrosion, dirt, cracks or blisters. NOTE: It is better to determine an inspection pattern in order to avoid missing an area, since the total inspection area is wide. Do not repair the body paint unless absolutely necessary. Also, if the vehicle is in need of repair to remove scratches or corroded paint, the repair area must be limited to the minimum. Re-painting and spray painting must be avoided as possible. 3) Check each window glass for scratches carefully. Slight damage may be removed by polishing with cerium oxide. (Fill a cup half with cerium oxide, and add warm water to it. Then agitate the content until it turns to wax. Apply this wax to a soft cloth, and polish the glass with it.) 4) Check each portion of the vehicle body and underside components for the formation of rust. If rust is discovered, remove it with sandpaper of #80 to #180 and treat the surface with rust preventive. After this treatment is completed, flush the portion thoroughly, and prepare the surface for repair painting. 5) Check each portion of body and all of the plated parts for deformation or distortion. Also, check each light lens for cracks.
HOT MAX COLD MAX HOT MIN COLD MIN PS-00463
50.FLUID LEAKAGE
Check entire areas of the vehicle for any trace of coolant/oil/fluid leaks.
51.WATER LEAK TEST

Spray the vehicle with water using a hose and check that no water enters the passenger compartment. Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. Close all the windows and doors securely. Close the hood and trunk lid before starting the test. Spray the vehicle with water using a hose. The rate of water spray must be approx. 20 25 2 (5.3 6.6 US gal, 4.4 5.5 Imp gal) per minute. When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When spraying water on areas other than the floor and wheel house, decrease the pressure. But the force of water must be made strong occasionally by pressing the end of the hose. NOTE: Be sure to keep the hose at least 10 cm (3.9 in) away from vehicle. Check the following areas. Front window and body framework mating portion Door mating portions Glass mating portions Rear quarter window mating portions Rear window and body framework mating portion Around roof drips If any dampness in the compartments is discovered after the water has been applied, carefully check all the areas that may have possibly contributed to the leak.
PI-17
6) Peel the protective tape, vinyl wrapping and identification seal attached to the following places. Seats Door trim Floor carpet Side sill Front hood lock release lever Edge rear Rear wiper Sedan rear combination light (Trunk lid opening portion) Roof rail Door mirror
PI-18
General Description
PERIODIC MAINTENANCE SERVICES
1. General Description
Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they occur.
PM-2
Schedule
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. U.S.
Other than U5 model
Maintenance interval [Number of months or km (miles), whichever occurs first] Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 1,000 km 4.8 12 24 36 48 60 72 81.4 96 108 120 132 144 156 168 180 192 Remarks 1,000 miles 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 1 Engine oil 3.0 L R R R R R R R R R R R R R R R R R 2.5 L R R R R R R R R R R R R R R R R Turbo model Note 6. 2 Engine oil 3.0 L R R R R R R R R R R R R R R R R R filter 2.5 L R R R R R R R R R R R R R R R R Turbo model Note 5. 3 Spark plug R R R R 2.5 L Non-turbo model R R For 2.5 L turbo, 3.0 L model 4 Drive belt(s) I I I R 5 Camshaft drive belt I I I R 6 Fuel line (I) (I) (I) I Note 1. 7 Air cleaner element R R R R Note 2. 8 Cooling system I I I I 9 Engine coolant Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter 10 Clutch system I I I I I I I I 11 Transmission oil I I I I 12 ATF I I I I Note 3. 13 Front & rear I I I I differential oil 14 Brake line I I I I I I I I 15 Brake fluid R R R R 16 Disc brake pad I I I I I I I I and disc 17 Parking brake I I I I I I I I 18 Suspension I I I I I I I I 19 Wheel bearing (I) (I) 20 Axle boots & joints I I I I I I I I 21 Tire rotation I I I I I I I I I I I I I I I I Note 4. 22 Steering system I I I I I I I I (Power steering) 23 A/C filter Replace every 12 months or 15,000 km (9,300 miles). Note 5. Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation.
PM-3
Schedule
NOTE: 1. This inspection is not required to maintain emission warranty eligibility and it dose not affect the manufacturers obligations under EPAs in-use compliance program. 2. When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. 3. ATF filter is maintenance free part. ATF filter needs replacement, when it has physically rust, damaged or ATF leaked. (5AT model) 4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when the remaining tread has been worn to 1.6 mm (0.063 in) or less. 5. When the A/C filter is installed. 6. For 2.5 L turbo model, replace every 3.75 months or 6,000 km (3,750 miles).
PM-4
Schedule
U5 model
Maintenance interval [Number of months or km (miles), whichever occurs first] 15 22.5 30 37.5 45 52.5 60 67.5 75 To be continued to the next table 24 36 48 60 72 81.4 96 108 120 15 22.5 30 37.5 45 52.5 60 67.5 75 R R R R R R R R R R R R R R R R R R R R I I I I (I) (I) R R I I Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter I I I I I I R I I I I I I I I I I I I R I I I (I) I I I I Note 3.
Months 1,000 km 1,000 miles Engine oil Engine oil filter Spark plug Drive belt(s) Camshaft drive belt Fuel line Air cleaner element Cooling system Engine coolant Clutch system Transmission oil ATF Front & rear differential oil Brake line Brake fluid Disc brake pad and disc Parking brake Suspension Wheel bearing Axle boots & joints Tire rotation Steering system (Power steering) A/C filter
7.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
4.8 12 3 7.5 R R
Remarks
Note 1. Note 2.
I I I I I I I
I I I I I I I
I I I I I I I
Note 4.
Replace every 12 months or 15,000 km (9,300 miles).
Note 5.
Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: 1. This inspection is not required to maintain emission warranty eligibility and it dose not affect the manufacturers obligations under EPAs in-use compliance program. 2. When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. 3. ATF filter is maintenance free part. ATF filter needs replacement, when it has physically rust, damaged or ATF leaked. (5AT model) 4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when the remaining tread has been worn to 1.6 mm (0.063 in) or less. 5. When the A/C filter is installed.
PM-5
Schedule
Maintenance interval [Number of months or km (miles), whichever occurs first] 82.5 90 97.5 105 112.5 120 127.5 135 142.5 132 82.5 R R
Months 1,000 km 1,000 miles Engine oil Engine oil filter Spark plug Drive belt(s) Camshaft drive belt Fuel line Air cleaner element Cooling system Engine coolant
Continued from the previous table
150 240 150 R R R Remarks
1 2 3 4 5 6 7 8 9 10 11 12 13
Clutch system Transmission oil ATF Front & rear differential oil 14 Brake line 15 Brake fluid 16 Disc brake pad and disc 17 18 19 20 21 22 Parking brake Suspension Wheel bearing Axle boots & joints Tire rotation Steering system (Power steering) 23 A/C filter
144 156 168 180 192 204 216 228 90 97.5 105 112.5 120 127.5 135 142.5 R R R R R R R R R R R R R R R R R R I R I I R I (I) I R R I I Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter I I I I I I I I I I R I I I I I I I I I I I I I I R I I I (I) I I I I I I I I I I
(I) R I
Note 1. Note 2.
I I I I I R I I I (I) I I I
Note 3.
Note 4.
Note 5.
PM-6
Schedule
2. CANADA
Maintenance interval [Number of months or km (miles), whichever occurs first] Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 1,000 km 4.8 12 24 36 48 60 72 81.4 96 108 120 132 144 156 168 180 192 Remarks 1,000 miles 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 1 Engine oil 3.0 L R R R R R R R R R R R R R R R R R 2.5 L R R R R R R R R R R R R R R R R R 2 Engine oil 3.0 L R R R R R R R R R R R R R R R R R filter 2.5 L R R R R R R R R R R R R R R R R R 3 Spark plug R R R R 2.5 L Non-turbo model R R For 2.5 L turbo, 3.0 L model 4 Drive belt(s) I I I R 5 Camshaft drive belt I I I R 6 Fuel line (I) (I) (I) I Note 1. 7 Air cleaner element R R R R Note 2. 8 Cooling system I I I I 9 Engine coolant Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter 10 Clutch system I I I I I I I I 11 Transmission oil I I I I 12 ATF I I I I Note 3. 13 Front & rear I I I I differential oil 14 Brake line 15 Brake fluid 16 Disc brake pad and disc 17 Parking brake 18 Suspension 19 Wheel bearing 20 Axle boots & joints 21 Tire rotation 22 Steering system (Power steering) 23 A/C filter I I I I I I I I I I R I I I I I I I I I I I I I I I I R I I I (I) I I I I I I I I I I I I I R I I I I I I I I I I I I I I I I R I I I (I) I I I Note 4.
Note 5.
PM-7
Schedule
B: MAINTENANCE SCHEDULE 2
Item Engine oil Maintenance interval 3.75 months 6,000 km 3,750 miles 3.75 months 6,000 km 3,750 miles 7.5 months 12,000 km 7,500 miles 15 months 24,000 km 15,000 miles 15 months 24,000 km 15,000 miles 15 months 24,000 km 15,000 miles 7.5 months 12,000 km 7,500 miles 15 months 24,000 km 15,000 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles Repeat short distance drive R Repeat rough/muddy road drive Extremely cold weather area R Salt or other corrosive used or coastal area High humidity or mountain area Repeat towing trailer R
Engine oil filter
Fuel line
Transmission oil
ATF
Front and rear differential oil Brake line
Brake fluid
Disc brake pad & disc Parking brake
Suspension
Axle boots & joints Steering system (Power steering)
PM-8
Engine Oil
3. Engine Oil
A: REPLACEMENT
1) Open the engine oil filter cap for quick draining of the engine oil. 2.5 L model
(A) (B)
2) Drain the engine oil by removing the engine oil drain plug. CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. NOTE: Prepare the container for draining of engine oil. 2.5 L model
PM-00161
(A) Oil level gauge (B) Oil filler cap

PM-00323
3.0 L model
(B) (A)
F
3.0 L model
(C)
(D)
LU-00111
PM-00280
(A) (B) (C) (D)
Oil level gauge Oil filler cap Upper level Lower level
3) Replace the drain plug gasket with a new part.
PM-9
Engine Oil
4) Tighten the engine oil drain plug after draining the engine oil. Tightening torque: 44 Nm (4.5 kgf-m, 33 ft-lb) 2.5 L model
5) Using engine oil of proper quality and viscosity, fill engine oil to the F line on oil level gauge. Place the vehicle on a level surface when checking oil level. Recommended oil: Refer to RM section. <Ref. to RM-2, LUBRICANTS, RECOMMENDED MATERIALS, Recommended Materials.> NOTE: The proper viscosity oil helps the engine maintain its ideal temperature, and cranking speed increased by reducing viscosity friction in hot condition. Engine oil capacity
PM-00323
3.0 L model
2.5 L model Upper level: Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt) Lower level: Approx. 3.0 2 (3.2 US qt, 2.6 Imp qt) 3.0 L model Upper level: Approx. 5.5 2 (5.8 US qt, 4.8 Imp qt) Lower level: Approx. 4.5 2 (4.8 US qt, 4.0 Imp qt)
PM-00280
CAUTION: It is acceptable to fill an engine with oil of another brand when replacing the oil, but make sure to use an oil with an API standard and SAE viscosity number specified by Subaru. NOTE: If the vehicle is used in regions of high temperatures or in other severe environments, use oil with the viscosities shown below. API standard: SM or SL SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W-50 6) Close the engine oil filler cap. 7) Start the engine, and spreads the oil in engine room. 8) Stop the engine to inspect the oil level again. If necessary, add engine oil up to the F line on the level gauge. <Ref. to PM-11, INSPECTION, Engine Oil.>
PM-10
Engine Oil
B: INSPECTION
1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation. 4) Remove the level gauge again and check the oil level. If the engine oil level is below L line, make sure that there is no oil leakage from the engine section, then add oil to rise the level up to the F line. 2.5 L model
(A) (B) (F)
6) After turning off the engine, wait a few minutes for the oil to return to the oil pan before checking the level. CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. NOTE: Just after driving or while the engine is warm, engine oil level may show in the range between the F line and the notch mark. This is caused by thermal expansion of engine oil. (2.5 L model) To prevent overfilling the engine oil, do not add oil above the F line when the engine is cold. As the oil level gauge is used for daily inspection, standard of F line and L line of the oil level gauge is set for the condition that engine is cold.
(C) (E) (D)
PM-00362
(A) (B) (C) (D) (E) (F)
Oil level gauge Oil filler cap Upper level Lower level Approx. 1 2 (1.1 US qt, 0.9 Imp qt) Notch mark
3.0 L model
(B) (A)
F L
(C) (E) (D)
PM-00363
(A) (B) (C) (D) (E)
Oil level gauge Oil filler cap Upper level Lower level Approx. 1 2 (1.1 US qt, 0.9 Imp qt)
5) Start the engine and warm it up for a time.
PM-11
Engine Oil Filter

4. Engine Oil Filter

A: REPLACEMENT
1) Remove the service hole clip located on the under cover. 2.5 L model
3) Remove the oil filter using ST. 3.0 L model ST 49857000 OIL FILTER WRENCH (Outer diameter: 80 mm (3.15 in)) 2.5 L model ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) General tool OIL FILTER WRENCH (65/67 mm 14 Flutes) (Outer diameter: 67.4 mm (2.65 in)) NOTE: However, in 2.5L model, SUBARU genuine oil filter having outer diameter of 68 mm (2.68 in) or 67.4 mm (2.65 in) can also be used. 2.5 L model
PM-00324
3.0 L model
PM-00326
3.0 L model
PM-00281
2) Rotate the service hole cover in the arrow direction. 2.5 L model
PM-00283
PM-00325
3.0 L model
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 4) Clean the oil filter installation surface on cylinder block and oil cooler. 5) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber.
PM-00282
PM-12
Engine Oil Filter

6) To install the oil filter, turn the filter by hand while being careful not to damage the seal rubber. When the seal rubber just touches the oil cooler, tighten by using a torque wrench or turn the filter by the specified amount. 3.0 L model Oil filter 80 mm (3.15 in) in outer diameter 14 Nm (1.4 kgf-m, 10.3 ft-lb) or tighten 3/4 rotation. 2.5 L model Oil filter 68 mm (2.68 in) in outer diameter 14 Nm (1.4 kgf-m, 10.3 ft-lb) or tighten 1 rotation. Oil filter 67.4 mm (2.65 in) in outer diameter 12 Nm (1.2 kgf-m, 8.9 ft-lb) or tighten approx. 7/8 rotation. CAUTION: Do not tighten excessively, or oil may leak. 7) Replace the service hole cover in the original position. 8) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. 9) Check the engine oil level. <Ref. to PM-11, INSPECTION, Engine Oil.> NOTE: The filter element and filter case are permanently jointed, therefore, interior cleaning is not necessary.
PM-13
Spark Plug
5. Spark Plug
A: REPLACEMENT
1. 2.5 L NON-TURBO MODEL
1) Remove the intake duct and intake chamber. 2) Remove the battery. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a spark plug socket.
2. 2.5 L TURBO MODEL

RH side 1) Remove the collector cover and the engine side cover. 2) Disconnect the ground cable from battery.
IN-00203
PM-00001
5) Tighten the new spark plug lightly with hand, and then secure with a spark plug socket to the specified torque. Recommended spark plug: <Ref. to SPC-3, ELECTRICAL, LEGACY.> Tightening torque: 21 Nm (2.1 kgf-m, 15.5 ft-lb) NOTE: Be sure to place the gasket between the cylinder head and spark plug. If the torque wrench is not available, tighten the spark plug until gasket contacts cylinder head, then tighten further 1/4 to 1/2 turns.
3) Remove the air cleaner case. <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.> 4) Disconnect the connector from ignition coil. 5) Remove the ignition coil. NOTE: Turn #3 ignition coil by 180 degrees to remove it.
IG-00092
6) Remove the spark plug with a spark plug socket. 7) Install in the reverse order of removal. Recommended spark plug: <Ref. to SPC-3, ELECTRICAL, LEGACY.> Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.6 kgf-m, 11.8 ft-lb)
PM-14
Spark Plug
LH side 1) Remove the collector cover and the engine side cover. 2) Remove the battery and battery carrier. 3) Remove the secondary air pump. <Ref. to EC(H4DOTC)-21, REMOVAL, Secondary Air Pump.> 4) Remove the bolts that attach the air pump duct to the rocker cover LH, and raise the air pump duct.
3. 3.0 L MODEL
RH side 1) Remove the collector cover and the engine side cover. 2) Disconnect the ground cable from battery.
IN-00203
3) Remove the air cleaner case. <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.> 4) Remove the bracket (A). 5) Disconnect the connector (B) from ignition coil.
(A)
IG-02072
(B)
IG-02004
5) Disconnect the connector from ignition coil. 6) Remove the ignition coil. NOTE: Turn #4 ignition coil by 180 degrees to remove it.
6) Remove the ignition coil. NOTE: Turn the #5 ignition coil to remove it.
IG-02073
7) Remove the spark plug with a spark plug socket. 8) Install in the reverse order of removal. Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.6 kgf-m, 11.8 ft-lb) Tightening torque (Air pump duct): 9 Nm (0.9 kgf-m, 6.6 ft-lb)
PM-15
Spark Plug
7) Remove the spark plug with a spark plug socket.
5) Remove the ignition coil. NOTE: Turn the #6 ignition coil to remove it. 6) Remove the spark plug with a spark plug socket.
IG-02005
IG-02007
(B)
(B)
(C)
(D)
(A) (B) IG-02011 (B) (C) (D)
(A) (B) (C) (D)
Ratchet handle Extension bar Universal joint Spark plug socket
(A)
IG-02011
8) Install in the reverse order of removal. Recommended spark plug: <Ref. to SPC-3, ELECTRICAL, LEGACY.> Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.6 kgf-m, 11.7 ft-lb) LH side 1) Remove the collector cover and the engine side cover. 2) Remove the battery and battery carrier. 3) Remove the bracket (A). 4) Disconnect the connector (B) from ignition coil.
(A)
(A) (B) (C) (D)
7) Install in the reverse order of removal. Recommended spark plug: <Ref. to SPC-3, ELECTRICAL, LEGACY.> Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.6 kgf-m, 11.8 ft-lb)
(B)
IG-02006
PM-16
V-belt
6. V-belt
A: INSPECTION
1. 2.5 L NON-TURBO AND 2.5 L TURBO MODEL
1) Replace the belts if cracks, fraying or wear are found. 2) Check the V-belt tension and adjust it if necessary by changing the generator installing position or idler pulley installing position. <Ref. to PM-18, REPLACEMENT, V-belt.> Belt tension (without belt tension gauge): (A) When installing new part: 7 9 mm (0.276 0.354 in) At inspection: 9 11 mm (0.354 0.433 in) (B) When installing new part: 7.5 8.5 mm (0.295 0.335 in) At inspection: 9.0 10.0 mm (0.354 0.394 in)
(C) P/S GEN A/C
Belt tension (with belt tension gauge): (A) When installing new part: 640 785 N (65.3 80.0 kgf, 144 176 lbf) At inspection: 490 640 N (50 65 kgf, 110 144 lbf) (B) When installing new part: 620 760 N (63 77 kgf, 140 170 lbf) At inspection: 350 450 N (36 46 kgf, 79 101 lbf)
(A) GEN A/C (B)
P/S
I/P C/P PM-00154
(A) (B)
(A) (B) C/P GEN P/S A/C I/P
Front side belt Rear side belt Crank pulley Generator Power steering oil pump pulley A/C compressor pulley Idler pulley
I/P C/P PM-00002
Front side belt Rear side belt Crank pulley Generator Power steering oil pump pulley A/C compressor pulley Idler pulley
PM-17
V-belt
2. 3.0 L MODEL
1) Replace the belts if cracks, fraying or wear are found. 2) Check that the V-belt automatic belt tensioner indicator (A) is within the range (D).
(A)
B: REPLACEMENT
1. FRONT SIDE BELT (FOR POWER STEERING OIL PUMP AND GENERATOR)
NOTE: Wipe off any oil and water on the belt and pulley. 1) Remove the collector cover. (If equipped) 2) Remove the V-belt covers. 2.5 L non-turbo model
(D)
(C) (B)
ME-03945
2.5 L turbo model
ME-00475
(A) (B) (C) (D)
Indicator Generator Power steering oil pump Service limit
ME-00807
3) Loosen the lock bolt (A). 4) Loosen the slider bolt (B). 5) Remove the front side belt (C). 6) Install a new V-belt, and tighten the slider bolt so as to obtain the specified belt tension. 7) Tighten the lock bolt (A). 8) Tighten the slider bolt (B). Tightening torque: Lock bolt 25 Nm (2.5 kgf-m, 18.4 ft-lb) Slider bolt 8 Nm (0.8 kgf-m, 5.8 ft-lb)
(C)
(B)
(A)
PM-00004
PM-18
V-belt
2. REAR SIDE BELT (FOR A/C)

NOTE: Wipe off any oil and water on the belt and pulley. 1) Remove the front side belts. 2) Loosen the lock nut (A). 3) Loosen the slider bolt (B). 4) Remove the rear side belt. 5) Install a new V-belt, and tighten the slider bolt so as to obtain the specified belt tension. 6) Tighten the lock nut (A). Tightening torque: 23 Nm (2.3 kgf-m, 17.0 ft-lb)
4) Install in the reverse order of removal.

(1) (6)
(4)
(2) (3)
(5)
ME-00474
(B)
(1) (2) (3) (4) (5) (6)
Power steering oil pump Belt tension adjuster Crank pulley A/C compressor Belt idler Generator
(A)
PM-00005
7) Install the front side belt. 2.5 L non-turbo model <Ref. to ME(H4SO)-39, FRONT SIDE BELT, INSTALLATION, V-belt.> 2.5 L turbo model <Ref. to ME(H4DOTC)-42, FRONT SIDE BELT, INSTALLATION, V-belt.>
3. 3.0 L MODEL
1) Fit the tool to the belt tensioner mounting bolt. 2) Turn the tool clockwise, and loosen the V-belt to remove.
ME-00473
3) Remove the V-belt cover.
PM-19
Timing Belt
7. Timing Belt
A: REPLACEMENT
1) Remove the radiator fan and A/C fan. <Ref. to CO(H4SO)-24, REMOVAL, Radiator Main Fan and Fan Motor.> 2) Protect the radiator with cardboard and blanket. 3) Remove the V-belts. <Ref. to ME(H4SO)-38, Vbelt.> 4) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 5) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 6) Remove the timing belt guide. (MT model)
7) Use the ST to turn crankshaft. Align the mark (a) of sprocket to the mark (b) of oil pump, and then ensure the right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) or left side cam sprocket mark (e), timing belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET
ST ME-00231
(d)
(c) PM-00008 (b) (a)
(f)
(e) ME-02387
8) Remove the belt idler.
PM-00521
PM-20
Timing Belt
9) Remove the belt idler No. 2.

1) Remove the radiator fan and A/C fan. <Ref. to CO(H4DOTC)-25, REMOVAL, Radiator Main Fan and Fan Motor.> 2) Protect the radiator with cardboard and blanket. 3) Remove the V-belts. <Ref. to ME(H4DOTC)-41, V-belt.> 4) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 5) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 6) Remove the timing belt guide. (MT model)
PM-00010
10) Remove the timing belt. 11) Remove the automatic belt tension adjuster assembly.
PM-00008
PM-00011
12) Install in the reverse order of removal. <Ref. to ME(H4SO)-45, INSTALLATION, Timing Belt.>
ME-03124
ME-00728
ME-00729
PM-21
Timing Belt
7) Using ST, turn the crankshaft and align the alignment marks on crank sprocket and left and right cam sprockets with notches of belt cover and oil pump. ST 499987500 CRANKSHAFT SOCKET
10) Remove the automatic belt tension adjuster assembly.
PM-00096
ST ME-00231
11) Install in the reverse order of removal. <Ref. to ME(H4DOTC)-47, Timing Belt.> CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur.
ME-00070
ME-03175
PM-00521
9) Remove the timing belt.
PM-22
Timing Belt
B: INSPECTION
1) Remove the timing belt cover (LH). 2) While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed. 3) When the side part of timing belt is abnormally worn (fluff or jumping out of core) or damaged, check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt with new part.
PM-00342
4) Install the timing belt cover (LH).

1) Remove the timing belt cover (LH). 2) While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace faulty timing belts with new parts as required. 3) When the side part of timing belt is abnormally worn (fluff or jumping out of core) or damaged, check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt.
PM-00343
4) Install the timing belt cover (LH).
PM-23
Fuel Line
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose band, etc. If faulty parts are found, repair or replace them. 2.5 L non-turbo model <Ref. to FU(H4SO)-65, Fuel Delivery and Evaporation Lines.> 2.5 L turbo model <Ref. to FU(H4DOTC)-80, Fuel Delivery, Return and Evaporation Lines.> 3.0 L model <Ref. to FU(H6DO)-65, Fuel Delivery and Evaporation Lines.>
PM-24
Air Cleaner Element

9. Air Cleaner Element

A: REPLACEMENT
1) Disconnect the ground cable from battery.
5) Remove the clips (B) on air cleaner case. Non-turbo model
(B)
(A)
PM-00373
Turbo model
IN-00203
2) Disconnect the connector from mass air flow sensor. Non-turbo model
(B)
(B) (A)
(A)
PM-00183
6) Remove the air cleaner element.
PM-00374
Turbo model
IN-00206
PM-00181
3) Remove the duct. 4) Loosen the clamps (A) which connect the air cleaner case to intake duct.
PM-25
Air Cleaner Element

7) Install in the reverse order of removal. CAUTION: When replacing the air cleaner element, use SUBARU Genuine air cleaner element according to the engine type. Using other air cleaner element may affect engine performance. NOTE: Check the clean side for contamination. Remove, if any. Fasten with a clip after inserting the lower tab of case.
IN-00207
Refer to COMPONENT for tightening torque. 2.5 L non-turbo model <Ref. to IN(H4SO)-2, COMPONENT, General Description.> 2.5 L turbo model <Ref. to IN(H4DOTC)-2, COMPONENT, General Description.> 3.0 L model <Ref. to IN(H6DO)-2, COMPONENT, General Description.>
PM-26
Cooling System
10.Cooling System
A: INSPECTION
1) To check the radiator for leakage, fill it with engine coolant, and attach the radiator cap tester (A) to the filler neck, and apply pressure. Check the following points: Non-turbo model: 157 kPa (1.6 kg/cm2, 23 psi) Turbo model: 122 kPa (1.2 kg/cm2, 18 psi) Each portion of radiator for leakage Hose joints and other connections for leakage NOTE: For turbo model, be sure to install the tester to filler tank side. Be particularly careful not to deform the filler neck of radiator when installing and removing the tester and after testing. Non-turbo model
2) Check the radiator cap valve open pressure using radiator cap tester. NOTE: Rust or dirt on the cap may prevent valve from functioning normally: be sure to clean the cap before testing. Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to six seconds. Replace the radiator cap if it is opened under a pressure less than the service limit value for this period. Radiator cap valve open pressure Non-turbo model Standard: 93 123 kPa (0.95 1.25 kg/cm2, 14 18 psi) Service limit: 83 kPa (0.85 kg/cm2, 12 psi) Turbo model Filler tank side Standard: 93 123 kPa (0.95 1.25 kg/cm2, 14 18 psi) Service limit: 83 kPa (0.85 kg/cm2, 12 psi) Radiator side Standard: 122 152 kPa (1.24 1.55 kg/cm2, 18 22 psi) Service limit: 112 kPa (1.14 kg/cm2, 16 psi)
(A)
PM-00128
Turbo model
(A)
PM-00184
PM-00023
When performing this check, be sure to keep the engine stationary and fill radiator with coolant. Wipe off check points before applying pressure. Use care not to spill coolant when detaching tester from radiator. Do not remove the radiator side cap. (Turbo model)
2.5 L model
(A)
(A)
(B) PM-00089
PM-27
Cooling System
3.0 L model
(A)
(B) PM-00369
(A) Check points for deformation (B) Check points for deformation, damage, rust
3) Start the engine, and then check it does not overheat or it is cooled excessively. If it overheats or it is cooled excessively, check the cooling system. CAUTION: If the engine coolant is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. 2.5 L non-turbo model <Ref. to CO(H4SO)-15, Water Pump.> <Ref. to CO(H4SO)-17, Thermostat.> <Ref. to CO(H4SO)19, Radiator.> <Ref. to CO(H4SO)-23, Radiator Cap.> 2.5 L turbo model <Ref. to CO(H4DOTC)-16, Water Pump.> <Ref. to CO(H4DOTC)-18, Thermostat.> <Ref. to CO(H4DOTC)-20, Radiator.> <Ref. to CO(H4DOTC)-24, Radiator Cap.> 3.0 L model <Ref. to CO(H6DO)-12, Water Pump.> <Ref. to CO(H6DO)-13, Thermostat.> <Ref. to CO(H6DO)15, Radiator.> <Ref. to CO(H6DO)-18, Radiator Cap.> 4) Check the radiator fan operates using Subaru Select Monitor, when the coolant temperature exceeds 96C (205F). If it does not operate, check the radiator fan system. 2.5 L non-turbo model <Ref. to CO(H4SO)-8, INSPECTION, Radiator Fan System.> 2.5 L turbo model <Ref. to CO(H4DOTC)-9, INSPECTION, Radiator Fan System.> 3.0 L model <Ref. to CO(H6DO)-8, INSPECTION, Radiator Fan System.>
PM-28
Engine Coolant
11.Engine Coolant
A: REPLACEMENT
WARNING: The radiator is of the pressurized type. Do not attempt to open the radiator cap immediately after the engine has been stopped. CAUTION: If the engine coolant is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Lift up the vehicle. 2) Remove the under cover. 3) Place a container under drain pipe. 4) Remove the drain plug to drain engine coolant into container.
10) Fill engine coolant into the reservoir tank up to FULL level. Recommended engine coolant: Refer to RM section. <Ref. to RM-4, COOLANT, RECOMMENDED MATERIALS, Recommended Materials.> Coolant capacity (fill up to FULL level): 2.5 L non-turbo model MT model Approx. 6.4 2 (6.8 US qt, 5.61 Imp qt) AT model Approx. 6.3 2 (6.7 US qt, 5.5 Imp qt) 2.5 L turbo model MT model Approx. 7.3 2 (7.7 US qt, 6.4 Imp qt) AT model Approx. 7.2 2 (7.6 US qt, 6.3 Imp qt) 3.0 L model Approx. 7.2 2 (7.6 US qt, 6.3 Imp qt) NOTE: The SUBARU Super Coolant contains anti-freeze and anti-rust agents, and is especially made for Subaru engines with an aluminum cylinder block. Always use SUBARU Super Coolant since other engine coolant may cause corrosion. 11) Close the radiator cap (or the coolant filler tank cap on turbo models), and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.) 12) Wait for one minute after the engine stops, then open the radiator cap (or the coolant filler tank cap on turbo models). If the engine coolant level drops, add engine coolant into the radiator (or the coolant filler tank on turbo models) up to the filler neck position. 13) Perform the procedures 11) and 12) again. 14) Install the radiator cap (or the coolant filler tank cap on turbo models) and reservoir tank cap properly. 15) Start the engine and operate the heater at maximum hot position and the blower speed setting to LO. 16) Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: Be careful with the engine coolant temperature gauge to prevent overheating. If the radiator hose becomes harden with the pressure of engine coolant, air bleeding operation seems to be almost completed. 17) Stop the engine and wait until the engine coolant temperature lowers to 30C (86F) or less.
CO-00248
5) For quick draining, open the radiator cap. NOTE: For turbo model, be sure to open the radiator cap on the filler tank side. Be careful not to spill coolant on the floor. 6) Drain the coolant from reservoir tank. 7) Tighten the radiator drain cock securely after draining coolant. 8) Pour cooling system conditioner through the filler neck. Cooling system protective agent: Cooling system conditioner (part No. SOA635071) 9) Pour the engine coolant into the radiator (or the coolant filler tank on turbo models) up to the filler neck position.
PM-29
Engine Coolant
18) Open the radiator cap (or the coolant filler tank cap on turbo models). If the engine coolant level drops, add engine coolant into the coolant filler tank up to the filler neck position and the reservoir tank to FULL level. 19) Install the radiator cap (or the coolant filler tank cap on turbo models) and reservoir tank cap properly. 20) Set the heater setting to maximum hot position and the blower speed setting to LO and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step 16).
B: ADJUSTMENT
1. PROCEDURE TO ADJUST THE CONCENTRATION OF THE SUBARU SUPER COOLANT
CAUTION: Use the SUBARU Super Coolant with a 50 60% concentration in order to obtain maximum antifreeze and anti-rust performance. To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper coolant concentration from the table, and adjust the concentration of the coolant (concentrated type) with a dilution water to the proper value.
Relationship of SUBARU Super Coolant concentration and freezing temperature SUBARU Super Coolant concentration 50% 55% Freezing temperature 36C (33F) 41C (42F) 60% 50C (58F)
Recommended engine coolant and dilution water: Refer to RM section for the recommended engine coolant and diluting water. <Ref. to RM-4, COOLANT, RECOMMENDED MATERIALS, Recommended Materials.>
PM-30
Clutch System
12.Clutch System
A: INSPECTION AND ADJUSTMENT
1) Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not. 5MT model (non-turbo model)
3) If the fluid level does not rise, or the push rod cannot be retracted, adjust the clutch pedal. <Ref. to CL-32, Clutch Pedal.> 4) Check the fluid level using the scale on the outside of the clutch reservoir tank (A). If the level is below MIN (B), inspect the clutch master cylinder, operating cylinder and hydraulic line for fluid leaks. If fluid leaks are found, repair or replace. If fluid leaks are not found, add clutch fluid to bring it up to MAX (C) of clutch reservoir tank. Recommended clutch fluid: Refer to RM section. <Ref. to RM-4, FLUID, RECOMMENDED MATERIALS, Recommended Materials.> CAUTION: Prevent the clutch fluid from being splashed over vehicle body. If clutch fluid is splashed over vehicle body, flush it, and then wipe it up. If any clutch fluid is spilt on the exhaust pipe, wipe it off with a cloth to avoid emitting smoke or causing a fire. NOTE: Avoid mixing brake fluid of different brands to prevent fluid performance from degrading. Be careful not to allow dirt or dust to get into the reservoir tank.
(C) (B) (A)
PM-00164
(A) Release lever (B) Push rod (C) Operating cylinder
5MT model (turbo model)

(B) (A)
(C)
(A) (C) (B)
PM-00499
PM-00165
6MT model
(A)
(B)
(C)
PM-00322
2) If the fluid level rises, pedal free play is correct.
PM-31
Transmission Gear Oil

13.Transmission Gear Oil

A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug. CAUTION: If the transmission gear oil is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. NOTE: Before starting work, cool off the transmission gear oil well. Drain the gear oil by removing drain plug using TORX bit T70. 5MT
3) Fill the transmission gear oil through the oil level gauge hole up to the upper point of level gauge. Recommended gear oil: Refer to RM section. <Ref. to RM-2, LUBRICANTS, RECOMMENDED MATERIALS, Recommended Materials.> NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. Gear oil capacity: 5MT model: 3.5 2 (3.7 US qt, 3.1 Imp qt) 6MT model: 4.1 2 (4.3 US qt, 3.6 Imp qt) 5MT (non-turbo model)
(A)
(B) (C)
MT-01548
PM-00030
6MT
(A)
5MT (turbo model)

(A) (B)
F
PM-00523 (B)
(A) Drain plug (Oil pan side) (B) Drain plug (Clutch housing side)
(C)
2) Replace the gasket with new part, and then tighten the drain plug to specified torque. Tightening torque: 5MT (Aluminum gasket) 44 Nm (4.5 kgf-m, 32.5 ft-lb) 5MT (Copper gasket) 70 Nm (7.1 kgf-m, 51.6 ft-lb) 6MT (Oil pan side): 50 Nm (5.1 kgf-m, 36.9 ft-lb) 6MT (Clutch housing side): 70 Nm (7.1 kgf-m, 51.6 ft-lb)
PI-00564
PM-32

6MT
(A)
(A)
(B) (C)
MT-00449
PM-33
Automatic Transmission Fluid

14.Automatic Transmission Fluid

A: INSPECTION
CAUTION: The level of ATF varies with fluid temperature. Pay attention to the fluid temperature when checking ATF level. 1) Raise the ATF temperature by driving a distance of 5 10 km (3 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 80C (158 176F) on Subaru Select Monitor. <Ref. to 4AT(diag)-17, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> 2) Make sure the vehicle is level. 3) After selecting all positions (P, R, N, D), shift the select lever in P range. Idle the engine for 1 2 minutes, and measure the ATF level. 4AT model
(A) (B) (C)
L F HOT
5) If the ATF level is below the center between upper and lower marks, add the recommended ATF until the fluid level is found above the center between upper and lower marks. CAUTION: Be careful not to exceed the upper level limit. Adding ATF to the upper limit mark on HOT side when the ATF temperature is less than 70C (158F) will overfill of ATF and cause a transmission failure. 6) Check ATF level after raising ATF temperature to 70 80C (158 176F) by running the vehicle or by idling the engine again. 7) Check the ATF for leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replace gasket, oil seals, plugs or other parts.
COLD L
(B) (C) AT-01323
(A) ATF level gauge (B) Upper level (C) Lower level
5AT model
(B) (C)
F L F HOT
(A)
(B)
COLD L
(C)
AT-04217
4) Make sure that ATF level is above the center of upper and lower marks at HOT side.
PM-34

B: REPLACEMENT
1. AUTOMATIC TRANSMISSION FLUID
CAUTION: If the ATF is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Drain the ATF by removing drain plug. NOTE: Before starting work, cool off the ATF well. 4AT model
4) Check the ATF level. <Ref. to PM-34, INSPECTION, Automatic Transmission Fluid.> 4AT model
(A) (B) (C)
L F HOT F
COLD L
(B) (C) AT-01323
(B)
5AT model
(A) PM-00524 (B) (C)
F L F HOT
(A)
(A) Front differential gear oil drain plug (B) ATF drain plug
(B)
COLD L
5AT model
(C)
AT-04217 (A)
2. ATF FILTER
PM-00168
(A) ATF drain plug
CAUTION: If the ATF is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. NOTE: Basically, the ATF filter is maintenance free, but when it is rusted or physically damaged or leaking, the ATF filter needs to be replaced. For the replacement procedure of ATF filter, refer to ATF Filter. <Ref. to 5AT-59, ATF Filter.>
2) Replace the gasket with new part, and then tighten the drain plug to specified torque. Tightening torque: 4AT model 25 Nm (2.5 kgf-m, 18.4 ft-lb) 5AT model 20 Nm (2.0 kgf-m, 14.8 ft-lb) 3) Pour in the ATF using the oil charge pipe. Recommended ATF: Refer to RM section. <Ref. to RM-4, FLUID, RECOMMENDED MATERIALS, Recommended Materials.> Capacity: Fill with the same amount of ATF as drained.
PM-35
Front & Rear Differential Gear Oil

15.Front & Rear Differential Gear Oil

A: REPLACEMENT
1. FRONT DIFFERENTIAL (MT MODEL)
Front differential gear oil of MT model lubricates the transmission and differential together. Refer to Transmission Oil for replacement procedure. <Ref. to PM-32, Transmission Gear Oil.>
2) Replace the gasket with new part, and then tighten the drain plug to specified torque. Tightening torque: 4AT model Copper gasket 70 Nm (7.1 kgf-m, 51.6 ft-lb) Aluminum gasket 44 Nm (4.5 kgf-m, 32.5 ft-lb) 5AT model Copper gasket 70 Nm (7.1 kgf-m, 51.6 ft-lb) 3) Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge. Recommended gear oil: Refer to RM section. <Ref. to RM-2, LUBRICANTS, RECOMMENDED MATERIALS, Recommended Materials.> NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. Gear oil capacity: 4AT model 1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
(A) (B) (C) (A)
2. FRONT DIFFERENTIAL (AT MODEL)

1) Drain the differential gear oil by removing drain plug using TORX bit T70. CAUTION: If the front differential gear oil is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. NOTE: Before starting work, cool off the differential gear oil well. 4AT model
PM-00169
5AT model
AT-04840
PM-00170
PM-36

5AT model 1.3 1.5 2 (1.4 1.6 US qt, 1.1 1.3 Imp qt)
(A) (A)
4) Pour oil to the bottom end of filler plug hole. Recommended gear oil: Refer to RM section. <Ref. to RM-2, LUBRICANTS, RECOMMENDED MATERIALS, Recommended Materials.> Except for VA2-type
(A)
F L
(B) (C)
PI-00184
(B) PM-00037
3. REAR DIFFERENTIAL
1) Drain the oil by removing drain plug. 2) Remove the filler plug for quick draining oil. 3) Install the drain plug after draining oil. NOTE: Apply liquid gasket to the drain plug threads for T-type (except for turbo 6MT model). Use a new gasket for VA-type and T-type (turbo 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: T-type (except for turbo 6MT model) 49.0 Nm (5.0 kgf-m, 36.2 ft-lb) T-type (turbo 6MT model) 60 Nm (6.1 kgf-m, 44.3 ft-lb) VA1-type 34 Nm (3.5 kgf-m, 25.1 ft-lb) VA2-type 50 Nm (5.1 kgf-m, 36.9 ft-lb)
(A) Filler plug (B) Drain plug
VA2-type
(A) (B) DI-00355
(A) Filler plug (B) Drain plug
Oil capacity: Except for turbo 6MT model 0.8 2 (0.8 US qt, 0.7 Imp qt) Turbo 6MT model 1.0 2 (1.1 US qt, 0.9 Imp qt) NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
PM-37

5) Install the filler plug. NOTE: Apply liquid gasket to the drain plug threads for T-type (except for turbo 6MT model). Use a new gasket for VA-type and T-type (turbo 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: T-type (except for turbo 6MT model) 49.0 Nm (5.0 kgf-m, 36.2 ft-lb) T-type (turbo 6MT model) 60 Nm (6.1 kgf-m, 44.3 ft-lb) VA1-type 34 Nm (3.5 kgf-m, 25.3 ft-lb) VA2-type 50 Nm (5.1 kgf-m, 36.9 ft-lb)
PM-38
Brake Line
16.Brake Line
A: INSPECTION
1. BRAKE LINE
1) Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/clamps. 3) Check any trace of fluid leakage, scratches, etc. on master cylinder, wheel cylinder and pressure control valve. NOTE: When the brake fluid level in the reservoir tank is lower than specified limit, the brake warning light on the combination meter will illuminate. Visually check the brake hose for damage. (Use a mirror where it is difficult to see)
2. SERVICE BRAKE
1) Check the free play of brake pedal by pulling up the pedal with a force of 10 N (1 kgf, 2 lb) or less. Brake pedal free play (Pulling up direction of pedal) 0.5 2.0 mm (0.02 0.08 in)
(A)
PM-00185
(A) Pedal free play
(2) (1)
PM-00171
(1) Front brake hose (2) Front brake pipe
2) If the free play is out of specifications above, adjust the brake pedal as follows. (1) Make sure the engine is off. (No vacuum is applied to brake booster.) (2) There should be play between brake booster clevis and pin at brake pedal installing portion. [Pulling up the brake pedal pad with a force of 10 N (1 kgf, 2 lb) or less to a stroke of 0.5 to 2.0 mm (0.02 to 0.08 in).] (3) If there is no free play between clevis pin and clevis, turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0.3 mm (0.012 in).
(A) (H) (B) (C)
(2)
(1)
(I) (J)
(D) (E) (F) (G)
PM-00186 PM-00172
(1) Rear brake pipe (2) Rear brake hose
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
Brake switch Adjusting nut 0.3 mm (0.012 in) Stopper Clevis pin Clevis Pedal free play Lock nut Brake booster operating rod Play at pin
PM-39
Brake Line
3) Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering wheel. With the brake pedal released, measure the distance between pedal and steering wheel again. The pedal stroke is normal if the difference between two measured values is the specified value or less. If the measured value is the specification or more, there is possibility of entering air in hydraulic unit. Brake pedal stroke A: 95 mm (3.7 in)/ 490 N (50 kgf, 110 lb) or less
1 2
3. BRAKE SERVO SYSTEM

1) With the engine off, depress the brake pedal several times applying the same pedal force. Make sure the travel distance should not change. 2) With the brake pedal depressed, start the engine. Make sure the pedal should move slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds. Make sure the pedal height should not change. 4) A check valve is incorporated into the brake booster nipple part. Disconnect the vacuum hose to inspect function of check valve. Make sure air flows from the booster end to engine end but does not flow in the opposite direction in the check valve.
=A (A)
1 2
(C)
(A)
(B) PM-00045
(D)
(A) Steering wheel (B) Toe board
(B) PM-00260
4) Check to see if air is in the hydraulic brake line by the feel of pedal operation. If air appears to exist in the line, bleed it from the system. 5) Check for even operation of all brakes, using a brake tester or by driving the vehicle for a short distance on a straight road.
(A) (B) (C) (D)
Brake booster Check valve Engine side Brake booster side
5) Check the vacuum hose for cracks or other damage. NOTE: When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections. 6) Check the vacuum hose to make sure it is tightly secured.
PM-40
Brake Fluid
17.Brake Fluid
A: REPLACEMENT
1) Either jack-up the vehicle and place a rigid rack under it, or lift up the vehicle. 2) Remove all the wheels. 3) Drain the brake fluid from master cylinder. 4) Refill the reservoir tank with recommended brake fluid. CAUTION: If brake fluid is spilt on the exhaust pipe, wipe it off with a cloth to avoid emitting smoke or causing a fire. Recommended brake fluid: Refer to RM section. <Ref. to RM-4, FLUID, RECOMMENDED MATERIALS, Recommended Materials.> NOTE: Avoid mixing different brands of brake fluid to prevent degrading the quality of fluid. Be careful not to allow dirt or dust to get into the reservoir tank. Perform the operation in the order from farthest wheel cylinder to the master cylinder. 5) Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid.
7) Loosen the bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into the container, and then quickly tighten the screw. 8) Repeat steps 6) and 7) until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube. NOTE: Add brake fluid as necessary while performing the air bleed operation, in order to prevent the tank from running short of brake fluid. 9) After completing the bleeding operation, hold the brake pedal depressed and tighten the screw and install bleeder cap. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb) 10) Bleed air from each wheel cylinder by following steps from 5) to 9). 11) Depress the brake pedal with a force of approx. 294 N (30 kgf, 66 lb) and hold it there for approx. 20 seconds. At this time check the pedal to see if it makes any unusual movement. Visually inspect the bleeder screws and brake pipe joints to confirm there is no fluid leakage. 12) Install the wheels, and drive the vehicle for a distance of 2 to 3 km (1 to 2 miles) to confirm that brakes are operating properly.
PM-00048
NOTE: Cover the bleeder with cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. While bleeding air, keep the reservoir tank filled with brake fluid to prevent entry of air. Operate the brake pedal slowly. For convenience and safety, perform work with 2 people. The amount of brake fluid required is approx. 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake system. 6) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed.
PM-41
Disc Brake Pad and Disc

18.Disc Brake Pad and Disc

A: INSPECTION
1) Jack-up the vehicle and support with rigid racks. Then remove the wheels. 2) Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if necessary. NOTE: When replacing a pad, always replace the pads for both the left and right wheels at the same time. Also replace the pad clips if they are twisted or worn.
3) Check the disc rotor, and correct or replace if it is damaged or worn. Front
Disc rotor thickness 16-inch Standard 17-inch 16-inch Wear limit 17-inch mm (in) 24 (0.94) 30 (1.18) 22 (0.87) 28 (1.10)
Rear
Disc rotor thickness Solid disc type Standard Ventilated disc type Solid disc type Wear limit Ventilated disc type mm (in) 10 (0.39) 18 (0.71) 8.5 (0.34) 16 (0.63)
(A) PM-00049
(A) Inspection hole
4) Remove the caliper body. <Ref. to BR-15, Front Disc Brake Assembly.> <Ref. to BR-22, Rear Disc Brake Assembly.> 5) Tighten the wheel nuts to secure disc rotor. 6) Set a dial gauge at a point of 10 mm (0.39 in) or less from outer periphery of the rotor, and then measure the disc rotor runout. Disc rotor runout limit: Front: 0.05 mm (0.002 in) Rear: 0.05 mm (0.002 in)
Front
Pad thickness 16-inch 17-inch 16-inch 17-inch mm (in) 11 (0.43) 11 (0.43) 1.5 (0.059) 1.5 (0.059)
Standard Wear limit
Rear
Pad thickness Solid disc type Ventilated disc type Solid disc type Ventilated disc type mm (in) 9 (0.35) 9 (0.35) 1.5 (0.059) 1.5 (0.059)
Standard Wear limit
PM-00051
(A) (C) (B)
PM-00140
(A) Pad thickness (B) Back metal (C) Lining
PM-42
Parking Brake
19.Parking Brake
A: INSPECTION
Inspect the brake linings and disc rotor of both sides of the rear brake at the same time by removing disc rotor. 1) Inspect the brake shoes for damage or deformation and check the brake linings for wear. NOTE: Always replace both primary and secondary brake shoes for the left and right wheels at the same time. Thickness of brake lining (except for back metal): Standard: 3.2 mm (0.126 in) Wear limit: 1.5 mm (0.059 in)
4) When the shoe return spring tension is excessively weakened, replace it.
B: ADJUSTMENT
For rear disc brake, adjust the parking brake after bleeding air. 1) Remove the rear cover (rubber) installed at back plate. 2) Turn the adjuster toward arrow mark (upward) until it is locked slightly, by using flat-tip screwdriver as shown in the figure.
(A) (B)
(C) (A) PM-00056
(B)
(C) PM-00054
(A) Adjuster (B) Cover (rubber) (C) Back plate
(A) Forward (B) Brake shoe (Primary side) (C) Brake shoe (Secondary side)
3) Turn back (downward) the adjuster 3 to 4 notches. 4) Install the cover (rubber) in original position correctly.
2) Check the inside of disc rotor for wear, dents or other damage. If the inside surface of dick rotor is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, correct or replace it. Brake drum inside diameter: Standard: 170 mm (6.69 in) Wear limit: 171 mm (6.73 in)
(B)
(A) PM-00055
(A) Inside diameter (B) Disc
3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them.
PM-43
Suspension
20.Suspension
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack-up the vehicle until front wheels are off ground. 2) Grasp the bottom of tire and move it in and out in axial direction. If relative movement (B) is observed between the brake disc cover (A) and the end of front arm (D), ball joint (C) may be excessively worn.
5) Damage of dust seal Visually inspect the ball joint dust seal. If it is damaged, remove the front arm. <Ref. to FS-18, Front Arm.> Also, measure the free play of the ball joint. <Ref. to FS-16, Front Ball Joint.> (1) If the free play exceeds standard value, replace the ball joint. (2) If the dust seal is damaged, replace with a new ball joint. NOTE: When the front arm ball joint has been removed or replaced, check the toe of front wheel. If the front wheel toe-in is not at the specified value, adjust the toe-in. <Ref. to FS-6, Wheel Alignment.>
(A) (A) (D) (C) (B) PM-00057
3) Grasp the end of front arm and move it up and down. Relative movement (A) between the housing (D) and front arm (C) boss indicates ball joint (B) may be excessively worn.
(D)
PM-00059
(A) Dust seal
2. FRONT, REAR SUSPENSION BUSHING

Apply pressure with tire lever etc. to inspect the bushing for abnormal fatigue or damage. Replace the bushings if there is abnormal fatigue or damage.
(A) (C) (B) PM-00058
4) If relative movement is observed in the step 2), 3), remove and inspect the ball joint. If the free play exceeds standard value, replace the ball joint. <Ref. to FS-16, Front Ball Joint.>
PM-00180
PM-44
Suspension
3. WHEEL ARCH HEIGHT

1) Unload the cargoes and set the vehicle in curb weight (empty) condition. 2) Check the wheel arch height of the front and rear suspensions to ensure that they are within specified values. <Ref. to FS-6, Wheel Alignment.> 3) When the wheel arch height is out of standard, visually inspect following components and replace deformed parts. Suspension components [Front strut assembly and rear damper assembly] Parts connecting suspension and body 4) When no components are deformed, adjust wheel arch height by replacing coil spring in the suspension whose wheel arch height is out of standard. <Ref. to FS-6, Wheel Alignment.> <Ref. to RS-7, Wheel Alignment.>
3) When the toe-in and thrust angle are out of standard value, adjust them so that they conform to standard value.
6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER

Visually inspect the front strut and rear shock absorber for oil leakage. Replace the front strut and rear shock absorber if oil leaks excessively.
7. TIGHTNESS OF BOLTS AND NUTS

Check the bolts and nuts for looseness. Retighten the bolts and nuts to specified torque. If the selflocking nuts and bolts are removed, replace them with new parts. Front suspension <Ref. to FS-3, COMPONENT, General Description.> Rear suspension <Ref. to RS-3, COMPONENT, General Description.>
4. WHEEL ALIGNMENT OF FRONT SUSPENSION

1) Check the alignment of front suspension to ensure that following items conform to standard values. Toe-in Camber Caster Steering angle <Ref. to FS-6, Wheel Alignment.> 2) When the caster angle does not conform to reference obviously, visually inspect the following components and replace deformed parts. Suspension components [Strut assembly, crossmember, front arm, etc.] Parts connecting suspension and body 3) When the toe-in and camber are out of standard value, adjust them so that they conform to standard value. 4) When the right-and-left turning angles of tire are out of standard, adjust to standard value.
8. DAMAGE TO SUSPENSION PARTS

Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. If necessary, replace the damaged parts with new parts. If minor rust formation, pitting, etc. are noted, remove the rust and take rust prevention measure. Front suspension Front arm Crossmember Strut Rear suspension Sub frame Front link Rear link Upper link Rear arm Shock absorber In the area where salt is sprayed to melt snow on a road in winter, check suspension parts for damage caused by rust every 12 months after lapse of 60 months. Take rust prevention measures as required.
5. WHEEL ALIGNMENT OF REAR SUSPENSION

1) Check the alignment of rear suspension to ensure that following items are within standard values. Toe-in Camber Thrust angle <Ref. to RS-7, Wheel Alignment.> 2) When the camber angle does not conform to standard value, visually inspect the following components. If the deformation is observed, replace the damaged parts. Suspension components [Shock absorber, front link, rear link, upper link, rear arm, sub frame, etc] Parts connecting suspension and body
PM-45
Wheel Bearing
21.Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE: Inspect the condition of front wheel bearing grease. 1) Jack-up the front side of vehicle. 2) While holding the front wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts, and remove the front wheel. 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub and measure axial play in axial direction. Service limit: Straight-ahead position within 0.05 mm (0.0020 in) 5) Remove the bolts and self-locking nuts, and extract the front arm from front crossmember. 6) Remove the PTJ of front drive shaft from transmission. <Ref. to DS-13, Front Axle.> 7) While supporting the front drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding. If the hub is noisy or binds, replace the front axle.
2. REAR WHEEL BEARING

1) Jack-up the rear side of vehicle. 2) While holding the rear wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts, and remove the rear wheel. 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub and measure axial play in axial direction. Service limit: Straight-ahead position within 0.05 mm (0.0020 in) 5) Remove the DOJ of rear drive shaft from rear differential. <Ref. to DS-26, Rear Drive Shaft.> 6) While supporting the rear drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding. If the hub is noisy or binds, replace the rear axle.
PM-00173
PM-00173
PM-46
Axle Boots & Joints

22.Axle Boots & Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace with new part. <Ref. to DS-22, Front Drive Shaft.> <Ref. to DS-26, Rear Drive Shaft.> Front
(A)
PM-00174
Rear
(B) PM-00175
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If faulty, replace with new part. <Ref. to DS-10, Propeller Shaft.>
PM-47
Tire Rotation
23.Tire Rotation
A: INSPECTION
1) When the tread has worn down to less than 1.6 mm (0.063 in) or the wear indicator appears across the tread, replace the tire. (Replace the right and left tire as a set.) 2) If the tire appears to be worn unevenly, adjust the wheel alignment. 3) Next, make a tire rotation between front and rear as shown in the figure, make sure tires are worn evenly. When the direction of tire rotation is not specified
4) Re-register the transmitter ID when rotation was performed. (3.0 L U4 model) <Ref. to TPM(diag)10, REGISTER TRANSMITTER ID, OPERATION, Subaru Select Monitor.>
WT-00113
(1) Front
When the direction of tire rotation is specified
WT-00115
(1) Front
(A) (C)
(B)
PM-00080
(A) New tread (B) Damaged tread (C) Tread wear indicator
PM-48
Steering System (Power Steering)

24.Steering System (Power Steering)

A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure they are correctly set in their specified positions. 2) Lightly turn the steering wheel to the left and right to determine the point where front wheels start to move. Measure the distance of the movement of steering wheel at the outer periphery of wheel. Steering wheel free play: 0 17 mm (0 0.67 in)
(1)
2. STEERING SHAFT JOINT

When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction). Also inspect for any damage to sealing or worn serrations. If the joint is loose, retighten the mounting bolts to the specified torque. Tightening torque: 24 Nm (2.4 kgf-m, 17.7 ft-lb)
PS-00450
(1) Steering wheel free play
Move the steering wheel vertically toward the shaft to ascertain if there is play in the direction. Maximum permissible play: 0.5 mm (0.020 in) 3) Drive the vehicle and check the following items during operation. (1) Steering force: The effort required for steering should be smooth and even at all points, and should not vary. (2) Pulled to one side: Steering wheel should not be pulled to either side while driving on a level surface. (3) Wheel runout: Steering wheel should not show any sign of runout. (4) Return factor: Steering wheel should return to its original position after it has been turned and then released.
PM-00176
3. GEARBOX
1) With the vehicle placed on a level surface, turn the steering wheel 90 in both the left and right directions. While the wheel is being rotated, reach under the vehicle and check for looseness in gearbox. Tightening torque: 60 Nm (6.1 kgf-m, 44.3 ft-lb)
PM-00177
2) Check the boot for damage, cracks or deterioration.
PM-49

3) With the vehicle placed on a level surface, quickly turn the steering wheel to the left and right. While steering wheel is being rotated, check the gear backlash. If any noise is noticed, adjust the gear backlash. 4) Apply liquid gasket to at least 1/3 of entire perimeter of adjusting screw thread. 5) Tighten the adjusting screw to 25 Nm (2.5 kgfm, 18.4 ft-lb) and then loosen. 6) Tighten the adjusting screw to 3.9 Nm (0.40 kgfm, 2.9 ft-lb) and then loosen 20.
2) Check the connections of knuckle ball joints for play, inspect for damage on dust seals, and check free play of ball studs. If castle nut is loose, retighten it to the specified torque, then tighten further up to a maximum of 60 until the cotter pin hole is aligned. Tightening torque: 27 Nm (2.75 kgf-m, 19.9 ft-lb) 3) Check the lock nut on the tie-rod for tightness. If it is loose, retighten it to the specified torque. Tightening torque: 85 Nm (8.7 kgf-m, 63 ft-lb)
5. POWER STEERING FLUID LEVEL

(A)
CAUTION: If the power steering fluid is spilt on the exhaust pipe, wipe it off with a clean cloth to avoid emitting smoke or causing a fire. NOTE: Check at power steering fluid temperature 20C (68F); read the fluid level on the COLD side. Check at power steering fluid temperature 80C (176F); read the fluid level on the HOT side. 1) Place the vehicle with engine OFF on a level surface. 2) Check the fluid level using the scale on the outside of the reservoir tank (A). If the level is below MIN (B), add fluid to bring it up to MAX (C).
PM-00068
(A) Apply liquid gasket to at least 1/3 of entire perimeter
7) Install the lock nut. While holding the adjusting screw with wrench, tighten the lock nut using ST. ST 926230000 SPANNER Tightening torque (lock nut): 25 Nm (2.5 kgf-m, 18.4 ft-lb) Hold the adjusting screw with wrench to prevent it from turning while tightening the lock nut.
4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends, scratches or other damage.
(C) (A)
(B) PM-00178
(A) (B)
NOTE: If fluid level is at MAX level or above, drain fluid to keep the level in the specified range of indicator by using a syringe or the like.
PM-00069
(A) Tie-rod end (B) Knuckle arm
Recommended fluid: Refer to RM section. <Ref. to RM-4, FLUID, RECOMMENDED MATERIALS, Recommended Materials.> Fluid capacity: 0.8 2 (0.8 US qt, 0.7 Imp qt)
PM-50

6. POWER STEERING FLUID FOR LEAKS

CAUTION: If the power steering fluid is spilt on the exhaust pipe, wipe it off with a clean cloth to avoid emitting smoke or causing a fire. Inspect the underside of oil pump and gearbox of power steering system, hoses, pipes and their couplings for fluid leaks. If the fluid leaks are found, retighten their fitting bolts (or nuts) and/or replace their parts. NOTE: Wipe the leaked fluid off after correcting fluid leaks. Also pay attention to clearances between hoses (or pipes) and other parts when inspecting fluid leaks.
2) Clips are fitted outside of positions (A) and (B) of boot. 3) Boot does not have crack or hole. NOTE: Rotate (B) position of gearbox boot against the torsion produced by the adjustment of toe-in etc. Apply grease to the groove (C).
(C)
(B) (A) PM-00090
7. HOSES OF OIL PUMP FOR DAMAGES

CAUTION: If the power steering fluid is spilt on the exhaust pipe, wipe it off with a clean cloth to avoid emitting smoke or causing a fire. Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new part if necessary. NOTE: Prevent hoses from turning and/or bending when installing hoses.
10.FITTING BOLTS AND NUTS

Inspect the fitting bolts and nuts of oil pump and bracket for looseness, and retighten them if necessary. Inspect and/or retighten them when engine is cold.
PM-00179
8. POWER STEERING PIPES FOR DAMAGES

CAUTION: If the power steering fluid is spilt on the exhaust pipe, wipe it off with a clean cloth to avoid emitting smoke or causing a fire. Check the power steering pipes for corrosion and damage. Replace the pipes with new parts if necessary.
9. GEARBOX BOOTS
Inspect both sides of the gearbox boot as follows, and correct the defects if necessary. 1) Positions (A) and (B) of the gearbox boot are fitted correspondingly in grooves (A) and (B) of the gearbox and rod (C).
PM-51

PM-52
General Description
FUEL INJECTION (FUEL SYSTEMS)
A: SPECIFICATION
Fuel tank Capacity Install locations Type Shutoff discharge pressure Discharge rate Fuel filter 64 2 (16.9 US gal, 14.1 Imp gal) Under rear seat Impeller 550 850 kPa (5.6 8.7 kg/cm2, 79.7 123.2 psi) 125 2 (33 US gal, 27.5 Imp gal)/h or more [12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)] In-tank type
Fuel pump
FU(H4SO)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T3 T3 (5) T1
T3 T1 (7) T3 T3 (8)
T3 (9) T1 (13) (13) (1) (15) (10) (11) (16) T1 (3) T3 T2 (6) T3
T3
T3
(10) (11) (12) T4 T4
(10) (11)
(10) (11)
T3 (4) (4)
(2) (2) (17) (18) T1 (14)
T1 FU-04028
FU(H4SO)-3
General Description
(1) (2) (3) (4) (5) (6) (7) (8) Intake manifold Gasket Nipple Guide pin Plug cord stay EGR valve Fuel pipe protector RH Fuel pipe protector LH (9) (10) (11) (12) (13) (14) (15) (16) Fuel injector pipe RH Fuel injector O-ring Purge control solenoid valve Plug cord holder Fuel pipe ASSY Fuel injector pipe LH Gasket (17) (18) Evaporation hose (A) Evaporation hose (B)
Tightening torque:Nm (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 17 (1.7, 12.5) T3: 19 (1.9, 14.0) T4: 25 (2.5, 18.4)
2. AIR INTAKE SYSTEM

T2
T1
(3)
(4)
(1)
(2)
FU-02560
(1) (2)
Gasket Throttle body
(3) (4)
Manifold absolute pressure sensor Tightening torque:Nm (kgf-m, ft-lb) O-ring T1: 2 (0.2, 1.5) T2: 8 (0.8, 5.9)
FU(H4SO)-4
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
T1
(1)
T2
(2)
T1
(4)
(3) T1 FU-00414
(1) (2)
Crankshaft position sensor Knock sensor
(3) (4)
Camshaft position sensor Camshaft position sensor support
Tightening torque:Nm (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 24 (2.4, 17.7)
FU(H4SO)-5
General Description
4. FUEL TANK
T1 (28)
(29) (17) (17) (15) (8) (17) (7) (10) (17) (9) (15) (17) (26) (25) (17) (1) (18) (30) (17) (11 ) (12) (17) (14) (19) T1 (16) (27)
(32)
(31) T4 (13)
(20) (2) (21) T4 T3 T3 T3
(3) T4 (6)
(5) (6) T3 (22)
(23)
(24)
(4)
T3
T2
T2
T3 FU-03250
FU(H4SO)-6
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Fuel tank Fuel tank band RH Fuel tank band LH Delivery tube Jet pump tube Retainer Fuel pump ASSY Fuel pump upper plate Fuel pump gasket Fuel level sensor Fuel sub level sensor Fuel sub level sensor upper plate Fuel sub level sensor gasket (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) Fuel filler hose Clamp Evaporation hose A Clip Evaporation hose F Fuel tank protector LH (Rear) Stopper RH Stopper LH Heat shield cover Fuel tank protector RH (Front) Fuel tank protector LH (Front) Evaporation hose B Connector (27) (28) (29) (30) (31) (32) Evaporation hose C Evaporation hose D Evaporation pipe Evaporation hose E Fuel sub level sensor filter Fuel sub level sensor protector
Tightening torque:Nm (kgf-m, ft-lb) T1: 4.4 (0.4, 3.2) T2: 9 (0.9, 6.6) T3: 17.5 (1.8, 12.9) T4: 33 (3.4, 24.3)
FU(H4SO)-7
General Description
5. FUEL LINE
T2 (28) T1 (30) T6 (23) (37) (38) T6 T2 (23) (23) T2 (22) T2 (23) C (26) (23) T1 (37) (23) (21) (35) (31) (23) (36) (27) (25)
(29) (24)
T2 (19)
(18) T2 (11) (8) (23) (39) (20) (1) (32) (1) (1) T2 (17) (34) (1) (33) (16) C
(1)
(31) T4
(33) T3 (14)
(15) (13) (13) (12) (10) (13)
(1)
(3)
(6) (5) (13)
(1)
(4)
(13) T5
(2) T5 (7) (9) FU-03120
FU(H4SO)-8
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) Clip Fuel damper Evaporation hose A Fuel delivery hose A Fuel delivery hose B Clip Bracket Evaporation tube Fuel pipe ASSY A Fuel delivery hose C Retainer Evaporation hose B Clamp Grommet Fuel pipe ASSY B Canister (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) Drain valve Drain filter Canister protector Pressure control solenoid valve Evaporation pipe A Evaporation pipe B Clip Fuel filler pipe Shut valve Gasket Filler ring Fuel filler cap Fuel tank pressure sensor Evaporation pipe protector Connector A Canister hose A (33) (34) (35) (36) (37) (38) (39) Connector B Canister hose B Drain hose Drain hose connector Evaporation hose C Evaporation hose D Evaporation hose E
Tightening torque:Nm (kgf-m, ft-lb) T1: 4.4 (0.4, 3.2) T2: 7.5 (0.8, 5.5) T3: 8 (0.8, 5.9) T4: 17.6 (1.8, 13) T5: 1.25 (0.1, 0.9) T6: 1 (0.1, 0.7)
FU(H4SO)-9
General Description
6. FUEL PUMP
(1)
(2) b (5) d (4) a b (2) C
(3)
(5)
(6)
(2) (8) d (10) C (7)
(9)
(12)
(13)
(11)
FU-04005
(1) (2) (3) (4) (5)
Sub tank bracket ASSY O-ring O-ring Fuel pump harness Spring
(6) (7) (8) (9)
Fuel filter Clip Spacer Pump ASSY
(10) (11) (12) (13)
Sub tank Cushion Fuel level sensor Fuel temperature sensor
FU(H4SO)-10
General Description
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. Place NO OPEN FLAMES signs near the working area. Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. Follow all government and local regulations concerning disposal of refuse when disposing fuel.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER 42099AE000 DESCRIPTION QUICK CONNECTOR RELEASE REMARKS Used for removing the quick connector.
ST42099AE000
18471AA000
FUEL PIPE ADAPTER
Used for draining fuel.
ST18471AA000
1B022XU0
SUBARU SELECT MONITOR III KIT
ST1B022XU0
FU(H4SO)-11
Throttle Body
2. Throttle Body
A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery.
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
IN-00203
3) Lift up the vehicle. 4) Remove the under cover. 5) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 6) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 7) Disconnect the throttle position sensor connector (A) and manifold absolute pressure sensor connector (B).
(B)
(A) FU-03448
8) Disconnect the engine coolant hoses (A) from the throttle body. 9) Remove the bolts (B) which secure the throttle body to the intake manifold, and remove the throttle body.
(A) (B)
(B) (A) FU-01084
FU(H4SO)-12
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Disconnect the ground cable from battery.
12) Disconnect the brake booster vacuum hose (A).
(A) FU-02320
13) Disconnect the PCV hose (A) from intake manifold.
IN-00203
4) Open the fuel filler lid, and remove the fuel filler cap. 5) Lift up the vehicle. 6) Remove the under cover. 7) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 8) Remove the air intake duct and air intake chamber. <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Duct.> <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 9) Remove the generator. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 10) Disconnect the spark plug cord from the spark plug. 11) Disconnect the engine coolant hoses (A) from throttle body.
(A)
(A)
FU-03956
14) Remove the bolt, and disconnect the bulk head harness connector from the engine harness connector and rear engine hanger.
FU-03924
15) Slide the engine harness connector in the direction of the arrow and remove the rear engine hanger.
(A)
FU-01085
FU-03925
FU(H4SO)-13
Intake Manifold
16) Disconnect the connectors from the engine coolant temperature sensor.
21) Disconnect the connector from the camshaft position sensor.
FU-00055
FU-02714
17) Disconnect the knock sensor connector.
22) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
(A)
FU-02713
(B)
18) Disconnect the connector from crankshaft position sensor.
FU-02734
23) Disconnect the connector from the oil switching solenoid valve. 24) Disconnect the connector from the variable valve lift diagnosis oil pressure switch. LH side
FU-00056
19) Disconnect the connector from power steering pump switch (A). 20) Disconnect the connector from the oil pressure switch (B). RH side
FU-02731
(A)
(B)
FU-03251
FU-02732
FU(H4SO)-14
Intake Manifold
25) Disconnect the connector from the oil temperature sensor.
28) Remove the bolts which secure intake manifold to cylinder head.
FU-02733
FU-03252
26) Remove the EGR pipe from intake manifold.
29) Remove the intake manifold.
B: INSTALLATION
1) Install the intake manifold onto cylinder heads. NOTE: Use a new gasket. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
FU-02974
27) Disconnect the fuel hoses from fuel pipe. (1) Disconnect the quick connector on the fuel delivery line by pushing the ST in the direction of the arrow. ST 42099AE000 QUICK CONNECTOR RELEASE (2) Remove the clip and disconnect the evaporation hose from the pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
FU-03252
2) Connect the fuel delivery hose and evaporation hose to the fuel pipe. <Ref. to FU(H4SO)-66, INSTALLATION, Fuel Delivery and Evaporation Lines.> NOTE: If fuel hoses or clamps are damaged, replace them with new parts. 3) Install the EGR pipe to intake manifold. Tightening torque: 34 Nm (3.5 kgf-m, 25.1 ft-lb)
ST
FU-02866
FU-02974
FU(H4SO)-15
Intake Manifold
4) Connect the connector to the oil temperature sensor.
8) Connect the connectors to camshaft position sensor.
FU-02733
FU-02714
5) Connect the connector to the variable valve lift diagnosis oil pressure switch. LH side
9) Connect the connector to the power steering pump switch (A). 10) Connect the connector to the oil pressure switch (B).
(A)
(B)
FU-02731
RH side
FU-03251
11) Connect the connector to crankshaft position sensor.
FU-02732
6) Connect the connector to the oil switching solenoid valve. 7) Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
FU-00056
12) Connect the knock sensor connector.
(A)
(B)
FU-02713 FU-02734
FU(H4SO)-16
Intake Manifold
13) Connect the connector to engine coolant temperature sensor.
17) Connect the engine coolant hoses (A) to throttle body.

(A)
FU-00055
(A)
FU-01085
14) Connect the PCV hose (A) to intake manifold.
18) Connect the spark plug cords to spark plugs. 19) Install the generator. <Ref. to SC(H4SO)-14, INSTALLATION, Generator.> 20) Install the air intake duct and air intake chamber. <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 21) Connect the ground cable to battery.
(A)
FU-03956
15) Connect the brake booster hose (A).
IN-00203
(A) FU-02320
16) Connect the engine harness connector to the bulkhead harness connector and fasten to the rear engine hanger with bolt. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
22) Lift up the vehicle. 23) Install the under cover. 24) Lower the vehicle. 25) Fill engine coolant. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
FU-03924
FU(H4SO)-17
Intake Manifold
C: DISASSEMBLY
1) Disconnect the engine ground terminal from intake manifold.
8) Disconnect the connectors (A) from fuel injector. 9) Remove the harness band (B) which holds the engine harness to the fuel injector pipe.
(B)
(A)
FU-01090
FU-03955
2) Remove the ignition coil and ignitor assembly. <Ref. to IG(H4SO)-6, REMOVAL, Ignition Coil and Ignitor Assembly.> 3) Remove the throttle body. <Ref. to FU(H4SO)12, REMOVAL, Throttle Body.> 4) Remove the EGR valve. <Ref. to FU(H4SO)-29, REMOVAL, EGR Valve.> 5) Remove the plug cord stay.
10) Remove the purge control solenoid valve. <Ref. to EC(H4SO)-7, REMOVAL, Purge Control Solenoid Valve.> 11) Remove the bolts which hold engine harness to intake manifold.
FU-03450
FU-03233
6) Remove the fuel pipe protector LH.
12) Remove the engine harness from intake manifold. 13) Remove the bolts which install fuel injector pipe on the intake manifold as shown in the figure RH side
FU-02325 FU-02717
7) Remove the fuel pipe protector RH.
FU-02326
FU(H4SO)-18
Intake Manifold
LH side
18) Remove the bolts which install fuel pipes on intake manifold.
FU-02718
FU-02722
19) Remove the fuel pipe from the intake manifold.
D: ASSEMBLY
NOTE: When assembling the nipple, apply liquid gasket. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent
FU-02719
14) Remove the fuel injectors from the fuel injector pipe. 15) Disconnect the quick connector that fastens the fuel injector pipe RH to the fuel pipe.
Tightening torque: 17 Nm (1.7 kgf-m, 12.5 ft-lb) 1) Tighten the bolts which install fuel pipes on intake manifold. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-02720
16) Disconnect the quick connector that fastens the fuel injector pipe LH to the fuel pipe.
FU-02722
2) Connect the fuel injector pipe LH to the fuel pipe. NOTE: Connect the quick connector securely.
FU-02721
17) Remove the fuel injector pipe RH and LH.

FU-02721
FU(H4SO)-19
Intake Manifold
3) Connect the fuel injector pipe RH to the fuel pipe. NOTE: Connect the quick connector securely.
Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-02719
FU-02720
4) Install the fuel injector. 5) Tighten the bolts which install fuel injector pipes on intake manifold. RH side Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
6) Install the engine harness to the intake manifold. 7) Tighten the bolts which install engine harness on intake manifold. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-03450
FU-02717
LH side Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
8) Install the purge control solenoid valve. <Ref. to EC(H4SO)-7, INSTALLATION, Purge Control Solenoid Valve.> 9) Connect the connectors (A) to fuel injector. 10) Hold the engine harness to injector pipe by harness band (B).
(B)
(A) FU-02718
FU-03955
FU(H4SO)-20
Intake Manifold
11) Install the fuel pipe protector RH. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
17) Install the engine ground terminal to intake manifold. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02326
12) Install the fuel pipe protector LH. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-01090
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not damaged and the connections are tightened firmly.
FU-02325
13) Install the plug cord stay. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-03233
14) Install the EGR valve. <Ref. to FU(H4SO)-29, INSTALLATION, EGR Valve.> 15) Install the throttle body to intake manifold. <Ref. to FU(H4SO)-12, INSTALLATION, Throttle Body.> 16) Install the ignition coil and ignitor assembly. <Ref. to IG(H4SO)-6, INSTALLATION, Ignition Coil and Ignitor Assembly.>
FU(H4SO)-21
Engine Coolant Temperature Sensor

4. Engine Coolant Temperature Sensor

A: REMOVAL
IN-00203
2) Remove the generator. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 3) Drain engine coolant. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 4) Disconnect the connectors from the engine coolant temperature sensor.
FU-00055
5) Remove the engine coolant temperature sensor.
B: INSTALLATION
FU(H4SO)-22
Crankshaft Position Sensor

5. Crankshaft Position Sensor

A: REMOVAL
IN-00203
2) Remove the bolt which installs crankshaft position sensor to cylinder block.
FU-00056
3) Remove the crankshaft position sensor, and then disconnect the connector from it.
FU-00057
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-03811
FU(H4SO)-23
Camshaft Position Sensor

6. Camshaft Position Sensor

A: REMOVAL
6) Remove the camshaft position sensor from the camshaft position sensor support.
FU-00179
IN-00203
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Camshaft position sensor support 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) Camshaft position sensor 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-02714
3) Remove the bolt which installs camshaft position sensor to support.
FU-02724
4) Remove the bolt which installs camshaft position sensor support to camshaft cap LH.
FU-02725
5) Remove the camshaft position sensor and the camshaft position sensor support as a unit.
FU(H4SO)-24
Knock Sensor
7. Knock Sensor
A: REMOVAL
B: INSTALLATION
1) Install the knock sensor to the cylinder block. NOTE: Extraction area of knock sensor cord must be positioned at a 60 angle relative to the engine rear. Tightening torque: 24 Nm (2.4 kgf-m, 17.7 ft-lb)
(A)
IN-00203
2) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 3) Disconnect the knock sensor connector.
(A) Front side
60
FU-02727
FU-03386
4) Remove the knock sensor from the cylinder block.

FU-03386
3) Install the air intake chamber. <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 4) Connect the ground cable to battery.
FU-02726
IN-00203
FU(H4SO)-25
Throttle Position Sensor

8. Throttle Position Sensor

A: SPECIFICATION
Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to Throttle Body for removal and installation procedure. <Ref. to FU(H4SO)-12, REMOVAL, Throttle Body.> <Ref. to FU(H4SO)-12, INSTALLATION, Throttle Body.>
FU(H4SO)-26
Manifold Absolute Pressure Sensor

9. Manifold Absolute Pressure Sensor

A: REMOVAL
IN-00203
2) Disconnect the connector from the manifold absolute pressure sensor and remove the manifold absolute pressure sensor from throttle body.
FU-03921
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use new O-rings. Tightening torque: 2 Nm (0.2 kgf-m, 1.5 ft-lb)
FU(H4SO)-27
Mass Air Flow and Intake Air Temperature Sensor

10.Mass Air Flow and Intake Air Temperature Sensor

A: REMOVAL
IN-00203
2) Disconnect the connector from the mass air flow and intake air temperature sensor, and remove the mass air flow and intake air temperature sensor.
FU-01106
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 1 Nm (0.1 kgf-m, 0.7 ft-lb)
FU(H4SO)-28
EGR Valve
11.EGR Valve
A: REMOVAL
IN-00203
2) Disconnect the connector from the EGR valve.
FU-01152
3) Remove the EGR valve from intake manifold.
FU-01153
B: INSTALLATION
FU(H4SO)-29
Fuel Injector
12.Fuel Injector
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Disconnect the ground cable from battery.
9) Remove the bolt which holds fuel injector pipe onto intake manifold.
FU-02717
10) Remove the fuel injector while lifting up the fuel injector pipe.
2. LH SIDE
IN-00203
3) Open the fuel filler lid, and remove the fuel filler cap. 4) Remove the intake boot. 5) Remove the spark plug cords from spark plugs (#1 and #3 cylinders). 6) Remove the fuel pipe protector RH.
1) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Remove the spark plug cords from spark plugs (#2 and #4 cylinders). 5) Remove the fuel pipe protector LH.
FU-02326
7) Disconnect the connectors (A) from fuel injector. 8) Remove the harness band (B) which holds the engine harness to injector pipe.
FU-02325
6) Disconnect the connectors (A) from fuel injector. 7) Remove the harness band (B) which holds the engine harness to injector pipe.
(B)
(B)
(A)
FU-02730 (A)
FU-03955
FU(H4SO)-30
Fuel Injector
B: INSTALLATION
1. RH SIDE
Install in the reverse order of removal. NOTE: Use new O-rings.
FU-02718
(B) (A) FU-03948
(A) O-ring (B) Fuel injector
FU-02719
Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02717
FU-02326
FU(H4SO)-31
Fuel Injector
2. LH SIDE
Install in the reverse order of removal. NOTE: Use new O-rings.
(B) (A) FU-03948
FU-02325
(A) O-ring (B) Fuel injector
FU-02719
FU-02718
FU(H4SO)-32
Variable Valve Lift Diagnosis Oil Pressure Switch

13.Variable Valve Lift Diagnosis Oil Pressure Switch

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. NOTE: Apply liquid gasket to the variable valve lift diagnosis oil pressure switch threads. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 17 Nm (1.7 kgf-m, 12.5 ft-lb)
IN-00203
2) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 3) Disconnect the connector from the variable valve lift diagnosis oil pressure switch. 4) Remove the variable valve lift diagnosis oil pressure switch. LH side
FU-02731
RH side
FU-02732
FU(H4SO)-33
Oil Temperature Sensor

14.Oil Temperature Sensor

A: REMOVAL
IN-00203
2) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 3) Remove the engine harness connector from the bracket. 4) Disconnect the connector from the oil temperature sensor. 5) Remove the oil temperature sensor.
FU-02733
B: INSTALLATION
Install in the reverse order of removal. NOTE: Apply liquid gasket to the oil temperature sensor threads. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
FU(H4SO)-34
Front Oxygen (A/F) Sensor

15.Front Oxygen (A/F) Sensor

A: REMOVAL
8) Remove the front oxygen (A/F) sensor. CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.
(B)
(A) IN-00203
FU-02735
3) Remove the air intake duct. <Ref. to IN(H4SO)8, REMOVAL, Air Intake Duct.> 4) Remove the clip fastening the harness and disconnect the front oxygen (A/F) sensor connector.
(B) (A)
(A) Front oxygen (A/F) sensor (B) Rear oxygen sensor
(C)
EX-02350
(A) Front oxygen (A/F) sensor connector (B) Rear oxygen sensor connector (C) Clip
5) Lift up the vehicle. 6) Remove the under cover. 7) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more.
FU(H4SO)-35

B: INSTALLATION
CAUTION: If lubricant is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protector of front oxygen (A/F) sensor. Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the front oxygen (A/F) sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.5 ft-lb)
6) Connect the ground cable to battery.
IN-00203
(B)
(A)
FU-02735
3) Install the under cover. 4) Lower the vehicle. 5) Connect the connector of front oxygen (A/F) sensor connector and fasten the harness with clips.
(B) (A)
(C)
EX-02350
FU(H4SO)-36
Rear Oxygen Sensor

16.Rear Oxygen Sensor

A: REMOVAL
8) Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.
(B)
(A) IN-00203
FU-02735
3) Remove the air intake duct. <Ref. to IN(H4SO)8, REMOVAL, Air Intake Duct.> 4) Remove the clip fastening the harness and disconnect the rear oxygen sensor connector.
(B) (A)
(C)
EX-02350
5) Lift up the vehicle. 6) Remove the under cover. 7) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more.
FU(H4SO)-37
Rear Oxygen Sensor

B: INSTALLATION
CAUTION: If lubricant is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protector of rear oxygen sensor. Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the rear oxygen sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.5 ft-lb)
IN-00203
(B)
(A)
FU-02735
3) Install the under cover. 4) Lower the vehicle. 5) Connect the rear oxygen sensor connector and fasten the harness with clips.
(B) (A)
(C)
EX-02350
FU(H4SO)-38
Engine Control Module (ECM)

17.Engine Control Module (ECM)

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. CAUTION: When the ECM of model with immobilizer has been replaced, be sure to perform the registration of immobilizer system. (Refer to the PC application help for Subaru Select Monitor.) NOTE: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system.
IN-00203
2) Remove the lower inner trim of passengers side. <Ref. to EI-61, REMOVAL, Lower Inner Trim.> 3) Detach the floor mat of passengers seat. 4) Remove the protect cover.
FU-03416
5) Remove the bolts and nuts which hold the ECM to the bracket.
FU-03417
6) Disconnect the ECM connectors, and take out the ECM.
FU(H4SO)-39
Main Relay
18.Main Relay
A: REMOVAL
IN-00203
2) Remove the glove box. <Ref. to EI-52, REMOVAL, Glove Box.> 3) Remove the harness cover (A).
(A)
FU-02092
4) Disconnect the connectors from main relay.
FU-02093
B: INSTALLATION
Install in the reverse order of removal.
FU(H4SO)-40
Fuel Pump Relay

19.Fuel Pump Relay

A: REMOVAL
IN-00203
(A)
FU-02092
4) Disconnect the connector from fuel pump relay.
FU-02094
B: INSTALLATION
FU(H4SO)-41
Electronic Throttle Control Relay

20.Electronic Throttle Control Relay

A: REMOVAL
IN-00203
(A)
FU-02092
4) Disconnect the connector from electronic throttle control relay.
FU-02095
B: INSTALLATION
FU(H4SO)-42
Fuel
21.Fuel
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Remove the fuse of fuel pump from main fuse box.
2. DRAINING FUEL (WITH SUBARU SELECT MONITOR)

WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. NOTE: If the fuel pump cannot be actuated, refer to DRAINING FUEL (THROUGH THE FUEL FILLER HOSE). <Ref. to FU(H4SO)-44, DRAINING FUEL (THROUGH THE FUEL FILLER HOSE), PROCEDURE, Fuel.> Be careful not to let the battery run-out. 1) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
FU-01122
2) Start the engine and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn the ignition switch to OFF. 5) Install the fuse of fuel pump to the main fuse box.
ST
FU-02866
3) Connect ST to the fuel delivery hose. ST 18471AA000 FUEL PIPE ADAPTER 4) Connect the gasoline proof hose to ST and put the end of the hose in the container. 5) Drive the fuel pump and drain the fuel using Subaru Select Monitor. <Ref. to EN(H4SO)(diag)-52, FUEL PUMP CONTROL (ON/OFF DRIVE), OPERATION, System Operation Check Mode.> CAUTION: Be careful not to spill fuel.
FU(H4SO)-43
Fuel
3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE)

WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. Fuel may remain in the fuel filler pipe. Draining the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (10 or less) before the operation. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> 4) Open the fuel filler lid, and remove the fuel filler cap. 5) Drain the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (10 or less). 6) Disconnect the fuel filler hose (A) from the fuel filler pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
(B)
(A) FU-02394
(A) Fuel filler hose (B) Evaporation hose
7) Set the container under the vehicle and insert the gasoline proof hose (10 or less) into the fuel filler hose to drain the fuel. CAUTION: Be careful not to spill fuel.
FU(H4SO)-44
Fuel Tank
22.Fuel Tank
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Drain fuel. <Ref. to FU(H4SO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 4) Disconnect the ground cable from battery.
8) Remove the service hole cover of fuel sub level sensor. (1) Remove the bolt (A). (2) Push the grommet (B) down and remove the service hole cover.
(A)
(A)
(B)
FU-01126
9) Disconnect connector (A) from fuel sub level sensor. 10) Disconnect the quick connector on the fuel delivery tube (B). <Ref. to FU(H4SO)-65, REMOVAL, Fuel Delivery and Evaporation Lines.>
(A)
IN-00203
5) Remove the rear seat. 6) Remove the service hole cover of fuel pump. (1) Remove the bolt (A). (2) Push the grommet (B) down and remove the service hole cover.
(B)
FU-02830
(A)
11) Remove the trunk room trim. (Sedan model) <Ref. to EI-70, REMOVAL, Trunk Room Trim.> 12) Remove the rear quarter trim. (Wagon model) <Ref. to EI-63, WAGON MODEL, REMOVAL, Rear Quarter Trim.> 13) Remove the pipe protector.
(A)
(B)
FU-01124
7) Disconnect the connector from fuel pump.
FU-02390
FU-03989
FU(H4SO)-45
Fuel Tank
14) Remove the grommet and disconnect the quick connector of the evaporation pipe. <Ref. to FU(H4SO)-65, REMOVAL, Fuel Delivery and Evaporation Lines.>
23) Disconnect the connector from the rear ABS wheel speed sensor.
FU-02894 FU-02391
24) Remove the bolts securing the parking brake cable clamp.
15) Remove the rear wheels. 16) Lift up the vehicle. 17) Remove the bolts which secure the rear brake hose mounting bracket.
FU-02895
FU-01128
18) Remove the rear disc brake assembly and tie it to the body side of the vehicle.
FU-02896
25) Remove the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) Remove the bolts which hold the rear shock absorber to the rear suspension arm.
FU-00462
19) Remove the parking brake cable from the parking brake assembly. <Ref. to PB-6, REMOVAL, Parking Brake Assembly (Rear Disc Brake).> 20) Remove the rear exhaust pipe. <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> 21) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 22) Remove the heat shield cover and fuel tank protector.
FU-01132
FU(H4SO)-46
Fuel Tank
(3) Remove the bolts which secure the rear suspension assembly to the body.
28) Disconnect the fuel filler hose (A) and evaporation hose (B).
(B)
(A) FU-01133 FU-02394
29) Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle. WARNING: A helper is required to perform this work. Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop the fuel tank when removing.
FU-02891
(4) Remove the rear suspension assembly. 26) Disconnect the connector.
FU-03293
FU-02392
27) Disconnect the evaporation hose.
FU-02393
FU(H4SO)-47
Fuel Tank
B: INSTALLATION
1) Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band. WARNING: A helper is required to perform this work.
3) Connect the evaporation hose.
FU-02393
4) Tighten the fuel tank band bolts. Tightening torque: 33 Nm (3.4 kgf-m, 24.3 ft-lb) 5) Connect the connector.
FU-03293
2) Securely insert the fuel filler hose (A) and evaporation hose (B) into the specified position, then attach the clamp or clip as shown in the figure.
(B)
FU-02392
(A) FU-02394
(1)
(2)
(3)
L/2 L
FU-00104
(1) Hose (2) Clamp or clip (3) Pipe
FU(H4SO)-48
Fuel Tank
6) Install the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) Support the rear suspension assembly, and tighten the bolts which secure the rear suspension assembly to the body. Tightening torque: T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb) T2: 175 Nm (17.8 kgf-m, 129.1 ft-lb)
T1 T1
7) Tighten the bolts holding the parking brake cable clamp. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
FU-02895 T1
T1
FU-01150
FU-02896
T2
T2
8) Connect the connector to the rear ABS wheel speed sensor.
FU-02892
(3) Tighten the bolts which hold the rear shock absorber to the rear suspension arm. <Ref. to RS-10, INSTALLATION, Rear Arm.> Tightening torque: 62 Nm (6.3 kgf-m, 45.7 ft-lb)
FU-02894
9) Install the heat shield cover. Tightening torque: 17.5 Nm (1.8 kgf-m, 12.9 ft-lb) 10) Install the fuel tank protector. Tightening torque: Nut: 9 Nm (0.9 kgf-m, 6.6 ft-lb) Bolt: 17.5 Nm (1.8 kgf-m, 12.9 ft-lb) 11) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 12) Install the rear exhaust pipe. <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> 13) Lower the vehicle.
FU-01132
FU(H4SO)-49
Fuel Tank
14) Connect the parking brake cable to the parking brake assembly. <Ref. to PB-7, INSTALLATION, Parking Brake Assembly (Rear Disc Brake).> 15) Install the rear disc brake assembly. Tightening torque: 66 Nm (6.7 kgf-m, 48.7 ft-lb) 16) Tighten the bolts which secure the rear brake hose mounting bracket. Tightening torque: 33 Nm (3.4 kgf-m, 24.3 ft-lb)
21) Install the trunk room trim. (Sedan model) <Ref. to EI-71, INSTALLATION, Trunk Room Trim.> 22) Install the rear quarter trim. (Wagon model) <Ref. to EI-64, INSTALLATION, Rear Quarter Trim.> 23) Connect connector (A) to the fuel sub level sensor. 24) Connect the quick connector of the fuel delivery hose (B). <Ref. to FU(H4SO)-66, INSTALLATION, Fuel Delivery and Evaporation Lines.>
(A)
(B) FU-01128
FU-02830
17) Lower the vehicle. 18) Install the rear wheels. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 19) Connect the quick connector of the evaporation pipe. <Ref. to FU(H4SO)-66, INSTALLATION, Fuel Delivery and Evaporation Lines.>
25) Install the service hole cover of fuel sub level sensor.
(A)
(A)
(B)
FU-01126
(A) Bolt (B) Grommet
26) Connect the connector to the fuel pump.

FU-02391
20) Install the pipe protector. Tightening torque: T1: 1 Nm (0.1 kgf-m, 0.7 ft-lb) T2: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
T2
FU-02829
T1
FU-02868
FU(H4SO)-50
Fuel Tank
27) Install the service hole cover of fuel pump.
(A)
(A)
(B)
FU-01124
28) Install the rear seat. 29) Connect the ground cable to battery.
IN-00203
30) Inspect the wheel alignment and adjust if necessary.
C: INSPECTION
1) Check that the fuel tank does not have holes, cracks or is damaged in any way. 2) Check that the fuel pipe and fuel hose are not cracked and those connections are tight.
FU(H4SO)-51
Fuel Filler Pipe

23.Fuel Filler Pipe

A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Drain fuel. <Ref. to FU(H4SO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 4) Disconnect the ground cable from battery.
11) Remove the bolts which hold fuel filler pipe bracket on the body.
FU-02395
12) Loosen the clamp, and disconnect the fuel filler hose (A) and evaporation hose (B).
(B)
(A) FU-02396 IN-00203
5) Open the fuel filler lid, and remove the filler cap. 6) Remove the screws which secure gasket.
(B)
FU-02397
13) Remove the fuel filler pipe to the underside of the vehicle.
FU-00095
7) Remove the rear wheel RH. 8) Lift up the vehicle. 9) Remove the mud guard. <Ref. to EI-29, REMOVAL, Mud Guard.> 10) Remove the rear sub frame. <Ref. to RS-21, REMOVAL, Rear Sub Frame.>
FU(H4SO)-52
Fuel Filler Pipe

B: INSTALLATION
1) Open the fuel filler lid. 2) Set the fuel saucer (A) with rubber gasket (C), and insert the fuel filler pipe into hole from the inner side of apron. 3) Align the holes in fuel filler pipe neck and set the cup (B), and tighten the screws. NOTE: If the edges of rubber seal are folded toward inside, straighten it with a flat tip screwdriver.
(A) (1)
(2)
(3)
L/2 L
FU-00104
(B) (C)
5) Tighten the bolts which hold fuel filler pipe bracket on the body. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
FU-00103
4) Securely insert the fuel filler hose (A) and evaporation hose (B) into the specified position, then attach the clamp or clip as shown in the figure. Tightening torque: 2.5 Nm (0.3 kgf-m, 1.8 ft-lb)
FU-02395
(B)
(A) FU-02396
6) Install the rear sub frame. <Ref. to RS-21, INSTALLATION, Rear Sub Frame.> 7) Install the mud guard. <Ref. to EI-29, INSTALLATION, Mud Guard.> 8) Lower the vehicle. 9) Install the rear wheel RH. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 10) Connect the ground cable to battery.
(B)
FU-02397
IN-00203
FU(H4SO)-53
Fuel Filler Pipe

C: INSPECTION
1) Check that the fuel tank does not have holes, cracks or is damaged in any way. 2) Make sure that the fuel hose is not cracked and that the connections are tight.
E: ASSEMBLY
1) Install the shut valve to the fuel filler pipe. <Ref. to EC(H4SO)-15, INSTALLATION, Shut Valve.> 2) Tighten the nuts which secure the evaporation pipe assembly to the fuel filler pipe. Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
D: DISASSEMBLY
1) Move the clip and disconnect the evaporation hose from the shut valve.
FU-02399 FU-02398
2) Remove the nut which holds the evaporation pipe assembly to the fuel filler pipe.
FU-02400
3) Connect the evaporation hose to the shut valve.

FU-02399
FU-02398
FU-02400
3) Remove the shut valve from the fuel filler pipe. <Ref. to EC(H4SO)-15, REMOVAL, Shut Valve.>
FU(H4SO)-54
Fuel Pump
24.Fuel Pump
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: Fuel pump assembly consists of fuel pump, fuel filter and fuel level sensor. 1) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Drain fuel. <Ref. to FU(H4SO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 3) Disconnect the ground cable from battery.
FU-03989
7) Disconnect the quick connector of fuel delivery tube and jet pump tube. <Ref. to FU(H4SO)-65, REMOVAL, Fuel Delivery and Evaporation Lines.> 8) Remove the nuts which install fuel pump assembly onto fuel tank.
(B)
(A)
FU-02670
(A) Fuel delivery tube (B) Jet pump tube
9) Remove the fuel pump assembly from the fuel tank.

IN-00203
4) Remove the rear seat. 5) Remove the service hole cover. (1) Remove the bolt (A). (2) Push the grommet (B) down and remove the service hole cover.
(A)
(A)
(B)
FU-01124
FU(H4SO)-55
Fuel Pump
B: INSTALLATION
Install in the reverse order of removal while being careful of the following. Make sure the sealing portion is free from fuel or foreign matter before installation. Install with the protrusion (A) of gasket aimed at the front side of the vehicle. Insert the protrusion (B) of the gasket into the upper plate. (3 places) Align the protrusion (C) of the fuel pump assembly to the cutout in the upper plate. Tighten the nuts to the specified torque in the order as shown in the figure. NOTE: Use a new gasket and retainer. Tightening torque: 4.4 Nm (0.4 kgf-m, 3.2 ft-lb)
1 4 (B) 6 5 (C) 8 (B)
7 (B) 2 (A)
3
FU-02835
C: INSPECTION
Connect the lead harness to the connector terminal of fuel pump, and apply the battery power supply to check whether the pump operates. WARNING: Wipe off fuel completely. Keep the battery as far apart from fuel pump as possible. Be sure to perform the ON/OFF operation on the battery side. Do not run the fuel pump for a long time under non-load condition.
2 1 4 3 6 5
FU-01330
FU(H4SO)-56
Fuel Level Sensor

25.Fuel Level Sensor

A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: The fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. <Ref. to FU(H4SO)-55, REMOVAL, Fuel Pump.> 2) Disconnect the connector from fuel pump bracket. 3) Remove the fuel level sensor and fuel temperature sensor.
(A) (C)
(B) FU-02671
(A) Connector (B) Fuel temperature sensor (C) Fuel level sensor
B: INSTALLATION
FU(H4SO)-57
Fuel Sub Level Sensor

26.Fuel Sub Level Sensor

A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. 1) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Drain fuel. <Ref. to FU(H4SO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 3) Disconnect the ground cable from battery.
6) Disconnect the connector from the fuel sub level sensor.
FU-02672
7) Disconnect the quick connector of fuel delivery tube and jet pump tube. <Ref. to FU(H4SO)-65, REMOVAL, Fuel Delivery and Evaporation Lines.> 8) Remove the nuts and bolts which install fuel sub level sensor on fuel tank.
(A)
(B) FU-02673
IN-00203
4) Remove the rear seat. 5) Remove the service hole cover. (1) Remove bolt (A). (2) Push the grommet (B) down and remove the service hole cover.
(A) Jet pump tube (B) Delivery tube
9) Remove the fuel sub level sensor.
(A)
(A)
(B)
FU-01126
FU(H4SO)-58

B: INSTALLATION
Install in the reverse order of removal while being careful of the following. Make sure the sealing portion is free from fuel or foreign matter before installation. Align the protrusion (A) of gasket with the position shown in the figure. Align protrusion (B) of the fuel sub level sensor to the cut out in the fuel sublevel sensor upper plate. Tighten the nuts and bolts to the specified torque in the order as shown in the figure. NOTE: Use a new gasket and retainer. Tightening torque: 4.4 Nm (0.4 kgf-m, 3.2 ft-lb)
3 1 5
6 2 4 (A)
FU-02836
(B)
FU-02674
FU(H4SO)-59
Fuel Filter
27.Fuel Filter
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. Be careful not to drop or apply any impact to the fuel pump during work. This may deteriorate its performance. NOTE: The fuel filter is built in fuel pump assembly. 1) Remove the fuel pump assembly. <Ref. to FU(H4SO)-55, REMOVAL, Fuel Pump.> 2) Remove the fuel level sensor and fuel temperature sensor. <Ref. to FU(H4SO)-57, REMOVAL, Fuel Level Sensor.> 3) Disconnect the pump assembly connector from the sub tank bracket assembly.
5) Disconnect the fuel piping connector from the fuel filter assembly in two locations.
FU-03851
6) Push to compress the fuel filter assembly in the direction of the arrow, remove clip (A), and separate the sub tank bracket assembly and the fuel filter assembly. CAUTION: When separating the sub tank bracket assembly and the fuel filter assembly, be careful not to damage the ground wire.
(A)
FU-03852
7) Disconnect the connector from the pump assembly.

FU-03983
4) Cut off the tab holders connecting the sub tank bracket assembly and the sub tank in four locations, and separate the two. CAUTION: Be careful not to damage the sub tank. NOTE: If the o-ring is remaining on the sub tank, remove.
FU-03986
FU-03984
FU(H4SO)-60
Fuel Filter
8) Lift the two tab holders connecting the pump assembly to the fuel filter using a flat tip screwdriver (with a shaft diameter of approx. 3 mm (0.12 in)), etc., and separate the fuel filter and pump assembly. CAUTION: To prevent damaging the tabs of the pump assembly, wrap the tip of flat tip screwdriver (A), etc. with tape (B).
(B) (A)
B: INSTALLATION
1) Assemble o-ring (A) and spacer (B) to the fuel pump, and attach the pump assembly to the fuel filter. NOTE: Use new O-rings (8 mm (0.31 in) inner diameter). Use a new spacer. Apply gasoline to the o-ring. Insert the pump assembly until a pop is heard.
(B) FU-03929
Be careful not to drop or apply any impact to the pump assembly. NOTE: If the spacer and o-ring is remaining on the pump assembly, remove these.
(A)
FU-03859
2) Connect the connector to the pump assembly.
FU-03927
FU-03986
FU(H4SO)-61
Fuel Filter
3) Attach spring (A) to the metal rod of the sub tank bracket assembly, and assemble the fuel filter assembly. NOTE: Use a new spring.
5) Connect the fuel piping connector to the fuel filter assembly. NOTE: Use new O-rings. Apply gasoline to the o-ring. The O-rings of the black and white connectors are identified by a difference in diameter. Be careful not to confuse the two during assembly. O-ring inner diameter: Black connector O-ring [Approx. 7 mm (0.28 in)] White connector O-ring [Approx. 8 mm (0.31 in)]
(A) (A) FU-03851
6) Attach the O-ring (A) to the fuel filter assembly, and attach the sub tank to the sub tank bracket assembly.
FU-03985
4) Push the fuel filter assembly in the direction of the arrow to compress, and attach clip (A). NOTE: Use a new clip.
(A)
NOTE: Use new O-rings (8 mm (0.31 in) inner diameter). Apply gasoline to the o-ring. Insert the pump assembly until a pop is heard.
FU-03861 (A)
FU-03987
FU(H4SO)-62
Fuel Filter
7) Replace the cushion on the rear face of the sub tank with a new cushion.
FU-03863
8) Connect the pump assembly connector to the sub tank bracket assembly.
FU-03983
9) Install the fuel level sensor and fuel temperature sensor. <Ref. to FU(H4SO)-57, INSTALLATION, Fuel Level Sensor.> 10) Install the fuel pump assembly. <Ref. to FU(H4SO)-56, INSTALLATION, Fuel Pump.>
FU(H4SO)-63
Fuel Damper
28.Fuel Damper
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. 1) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the fuel damper from the fuel delivery line.
FU-02870
B: INSTALLATION
CAUTION: If fuel hoses or clamps are damaged, replace them with new parts. Install in the reverse order of removal. Tightening torque: 1.25 Nm (0.1 kgf-m, 0.9 ft-lb)
FU(H4SO)-64
Fuel Delivery and Evaporation Lines

29.Fuel Delivery and Evaporation Lines

A: REMOVAL
FU-02831
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Remove the floor mat. <Ref. to EI-72, REMOVAL, Floor Mat.> 5) In the engine compartment, disconnect the fuel delivery hoses and evaporation hose. (1) Disconnect the quick connector of the fuel delivery line by pushing the ST in the direction of the arrow. ST 42099FE000 QUICK CONNECTOR RELEASE (2) Remove the clip and disconnect the evaporation hose from the pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
ST
(A)
(B)
FU-03435
(A) Fuel delivery hose (B) Evaporation hose
FU(H4SO)-65

6) Remove the canister. <Ref. to EC(H4SO)-5, REMOVAL, Canister.> 7) Remove the fuel tank. <Ref. to FU(H4SO)-45, REMOVAL, Fuel Tank.> 8) Remove the fuel pipe assembly. 9) Disconnect the quick connector, and disconnect the fuel delivery tube and jet pump tube. (1) Clean the pipe and connector, if they are covered with dust. (2) To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag etc.
B: INSTALLATION
Install in the reverse order of removal while being careful of the following.
1. CONNECTING THE FUEL LINE QUICK CONNECTOR

CAUTION: Make sure there is no damage or dust on the connections. If necessary, clean seal surface of pipe. NOTE: Use a new retainer.
(A)
(B)
FU-01333
(3) Hold the connector (A) and push the retainer (B) down. (4) Pull out the connector (A) from the retainer (B).
FU-00125
(A) Seal surface (B) Pipe
1) Set the new retainer (B) to connector (A). 2) Push the pipe into the connector completely.
(A) (B) (A) (C) (C) (B)
FU-00124
(A) Connector (B) Retainer (C) Pipe
FU-00126
FU(H4SO)-66

CAUTION: Pull the connector to ensure it is connected securely. Make sure the two retainer pawls are engaged in their mating positions in the connector. Be sure to inspect hoses and their connections for any leakage of fuel.
3. CONNECTING THE EVAPORATION HOSE

Connect the evaporation hose to the pipe with an overlap of 15 to 20 mm (0.59 to 0.79 in). L = 17.5r2.5 mm (0.689r0.098 in)
(1) (2) (3)
L/2 (A) L FU-00129
(B)
(C)
FU-00127
(1) Hose (2) Clip (3) Pipe
C: INSPECTION
1) Make sure that there are no cracks on the fuel pipes and fuel hoses. 2) Make sure the fuel pipe and fuel hose connections are tightened firmly.
2. CONNECTING THE FUEL DELIVERY HOSE.

Connect the fuel delivery hose to the pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When the amount to be inserted is specified. Type B: When the amount to be inserted is not specified. L1: 2.5r1.5 mm (0.098r0.059 in) L2: 22.5r2.5 mm (0.886r0.098 in) CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel.
(3) (1) L1 L2 (2) L1 FU-03390 (4) (5)
(1) (2) (3) (4) (5)
Type A Type B Pipe Clamp Hose
FU(H4SO)-67
Fuel System Trouble in General

30.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause 1. Insufficient fuel supply to injector 1) Fuel pump does not operate. Defective terminal contact Trouble in electromagnetic or electronic circuit parts Decline of fuel pump function Clogged fuel filter Clogged or bent fuel pipe or hose Air is mixed in the fuel system. Clogged or bent air breather tube or pipe. Damaged diaphragm of pressure regulator Corrective action
2) 3) 4) 5) 6) 7)
Inspect contact, especially ground, and tighten it securely. Replace the faulty parts. Replace the fuel pump. Replace the fuel filter. Clean or replace the fuel tank if necessary. Clean, correct or replace the fuel pipe or hose. Inspect or retighten each connection part. Clean, correct or replace the air breather tube or pipe. Replace. Retighten. Replace. Replace. Clean, correct or replace the air breather tube or air vent tube.
2. Leakage or blow out of fuel 1) Loose joints of the fuel pipe 2) Cracked fuel pipe, hose and fuel tank 3) Defective welding part on the fuel tank 4) Clogged or bent air breather tube or air vent tube
3. Gasoline smell inside of compartment Loose joints at air breather tube, air vent tube and fuel filler 1) pipe 2) Fuel saucer gasket air tightness fault 3) Inoperative fuel pump modulator or circuit 4. Defective fuel meter indicator 1) Defective operation of fuel level sensor 2) Defective operation of fuel meter 5. Noise 1) Large operation noise or vibration of fuel pump
Retighten. Correct or replace the gasket. Replace. Replace. Replace. Replace.
NOTE: When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. Fill fuel fully to prevent the problem. In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop to 0C (32F) or less throughout the winter season, use a water removing agent in the fuel system to prevent freezing fuel system and accumulating water. When water is accumulated in fuel filter, fill the water removing agent in the fuel tank. Before using water removing agent, follow the cautions noted on the bottle.
FU(H4SO)-68
General Description
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
A: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
B: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 18353AA000 DESCRIPTION CLAMP PLIERS REMARKS Used for removing and installing the PCV hose. This is a general tool made by the French company CAILLAU. (code) 54.0.000.205 To make this easier to obtain, it has been provided with a tool number.
ST18353AA000
EC(H4SO)-2
Front Catalytic Converter

2. Front Catalytic Converter

A: REMOVAL
The front catalytic converter is integrated into the front exhaust pipe; therefore, refer to Front Exhaust Pipe for the removal procedure. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
The front catalytic converter is integrated into the front exhaust pipe; therefore, refer to Front Exhaust Pipe for the installation procedure. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
1) Check the connections and welds for exhaust leaks. 2) Check for hole or rust.
EC(H4SO)-3
Rear Catalytic Converter

3. Rear Catalytic Converter

A: REMOVAL
The rear catalytic converter is integrated into the center exhaust pipe; therefore, refer to Center Exhaust Pipe for the removal procedure. <Ref. to EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.>
B: INSTALLATION
The rear catalytic converter is integrated into the center exhaust pipe; therefore, refer to Center Exhaust Pipe for the installation procedure. <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.>
C: INSPECTION
EC(H4SO)-4
Canister
4. Canister
A: REMOVAL
9) Remove the canister from body.
IN-00203
3) Lift up the vehicle. 4) Remove the rear wheel LH. 5) Remove the rear mud guard LH. <Ref. to EI-29, REAR MUD GUARD, REMOVAL, Mud Guard.> 6) Disconnect quick connector (A). 7) Disconnect the drain valve connector (B). 8) Remove clip (C).
(B)
EC-02080
(A)
(C) (A) EC-02079
EC(H4SO)-5
Canister
B: INSTALLATION
Install in the reverse order of removal. NOTE: Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
EC-02080
C: INSPECTION
Make sure the canister and canister hoses are not cracked or loose.
EC(H4SO)-6
Purge Control Solenoid Valve

5. Purge Control Solenoid Valve

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. Tightening torque (Purge control solenoid valve attachment bolt): 19 Nm (1.9 kgf-m, 14.0 ft-lb)
IN-00203
2) Disconnect the connector and evaporation hoses of purge control solenoid valve, and then remove the purge control solenoid valve.
EC-02392
NOTE: Connect the evaporation hose as shown in the figure.
(B) EC-02392 (A) EC-02289
(A) To fuel pipe (intake manifold) (B) To fuel pipe (evaporation line)
C: INSPECTION
Make sure the hoses are not cracked or loose.
EC(H4SO)-7
EGR Valve
6. EGR Valve
A: REMOVAL
For removal procedures, refer to FU section. <Ref. to FU(H4SO)-29, REMOVAL, EGR Valve.>
B: INSTALLATION
For installation procedures, refer to FU section. <Ref. to FU(H4SO)-29, INSTALLATION, EGR Valve.>
EC(H4SO)-8
Fuel Level Sensor

7. Fuel Level Sensor

A: REMOVAL
For removal procedures, refer to FU section. <Ref. to FU(H4SO)-57, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
For installation procedures, refer to FU section. <Ref. to FU(H4SO)-57, INSTALLATION, Fuel Level Sensor.>
EC(H4SO)-9
Fuel Temperature Sensor

8. Fuel Temperature Sensor

A: REMOVAL
The fuel temperature sensor is integrated into fuel level sensor as one unit; therefore, refer to Fuel Level Sensor for removal procedure. <Ref. to FU(H4SO)-57, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to Fuel Level Sensor for installation procedure. <Ref. to FU(H4SO)-57, INSTALLATION, Fuel Level Sensor.>
EC(H4SO)-10

9. Fuel Sub Level Sensor

A: REMOVAL
For removal procedures, refer to FU section. <Ref. to FU(H4SO)-58, REMOVAL, Fuel Sub Level Sensor.>
B: INSTALLATION
For installation procedures, refer to FU section. <Ref. to FU(H4SO)-59, INSTALLATION, Fuel Sub Level Sensor.>
EC(H4SO)-11
Fuel Tank Pressure Sensor

10.Fuel Tank Pressure Sensor

A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery.
C: INSPECTION
IN-00203
3) Open the fuel filler lid, and remove the fuel filler cap. 4) Lift up the vehicle. 5) Disconnect the connector from the fuel tank pressure sensor. 6) Disconnect the pressure hose from the fuel tank pressure sensor. 7) Remove the fuel tank pressure sensor along with the bracket.
EC-02084
B: INSTALLATION
EC-02084
EC(H4SO)-12
Pressure Control Solenoid Valve

11.Pressure Control Solenoid Valve

A: REMOVAL
C: INSPECTION
IN-00203
3) Lift up the vehicle. 4) Disconnect connector (A) from the pressure control solenoid valve. 5) Disconnect the evaporation hose (B) from the pressure control solenoid valve. 6) Remove the bolts (C) which secure the bracket to the fuel tank.
(A) (B)
(B) (C)
EC-02086
7) Remove the pressure control solenoid valve and bracket as a unit. 8) Remove the pressure control solenoid valve from the bracket.
EC-02087
B: INSTALLATION
EC(H4SO)-13
Drain Filter
12.Drain Filter
A: SPECIFICATION
Canister is a non-disassembled part, so do not remove the drain filter from canister. Refer to Canister for removal and installation procedures. <Ref. to EC(H4SO)-5, REMOVAL, Canister.> <Ref. to EC(H4SO)-6, INSTALLATION, Canister.>
EC(H4SO)-14
Shut Valve
13.Shut Valve
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Remove the fuel filler pipe. <Ref. to FU(H4SO)-52, REMOVAL, Fuel Filler Pipe.> 2) Disconnect the evaporation hose from the shut valve.
EC-02088
3) Remove the shut valve from the fuel filler pipe.
EC-02089
B: INSTALLATION
EC-02089
C: INSPECTION
EC(H4SO)-15
Drain Valve
14.Drain Valve
A: SPECIFICATION
Canister is a non-disassembled part, so do not remove the drain valve from canister. Refer to Canister for removal and installation procedures. <Ref. to EC(H4SO)-5, REMOVAL, Canister.> <Ref. to EC(H4SO)-6, INSTALLATION, Canister.>
EC(H4SO)-16
PCV Hose Assembly

15.PCV Hose Assembly

A: REMOVAL
CAUTION: Do not remove unless the PCV hose, diagnostics connector and PCV valve are damaged. 1) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Fit the depression in the ST with the protrusion on the clamp to unlock. 3) Remove the PCV hose assembly. ST 18353AA000 CLAMP PLIERS
EC-02151
B: INSTALLATION
1) Install the PCV hose assembly, then lock by fitting the ST on the clamp protrusion. NOTE: Replace the clamp with a new part. ST 18353AA000 CLAMP PLIERS
EC-02152
2) Install the air intake chamber. <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.>
EC(H4SO)-17
PCV Hose Assembly

EC(H4SO)-18
General Description
INTAKE (INDUCTION)
A: COMPONENT
T2 (14) (12) (11) (10) (13) (15) (14) (13) T2
T4
T4 T4 (18) (19) (16) T3 (17) T3
T3
(9) (9) T6 (8) (21)
(7) T5 (4) (20)
(3) (2)
T1
(6) (5) (1) IN-02263
IN(H4SO)-2
General Description
INTAKE (INDUCTION)
(1) (2) (3) (4) (5) (6) (7) (8) Air intake duct Clip Resonator chamber Air cleaner case (front) Spacer Cushion Air cleaner element Air cleaner case (rear) (with HC adsorption filter: U5 model and C5 model) Clip (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) Clamp Intake boot Clamp Cushion Spacer Air intake chamber Stay LH (MT model) Stay LH (AT model) Clamp Stay RH Cushion (21) Mass air flow and intake air temperature sensor
Tightening torque:Nm (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 6.5 (0.7, 4.8) T3: 16 (1.6, 11.8) T4: 3 (0.3, 2.2) T5: 7.5 (0.8, 5.5) T6: 1 (0.1, 0.7)
(9)
B: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.
IN(H4SO)-3
Air Cleaner Element

INTAKE (INDUCTION)

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Be sure to use SUBARU genuine air cleaner element depending on the engine type when replacing the air cleaner elements. Using other air cleaner element may affect the engine performance. NOTE: Check that there are no foreign objects in the air cleaner case. When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.
IN-00203
2) Disconnect the connector from mass air flow and intake air temperature sensor.
IN-02191 IN-02264
3) Loosen the clamps (A) which connect the air cleaner case and the intake boot. 4) Remove the clip (B) securing the upper side of air cleaner case.
Tightening torque: Clamp (A): 3 Nm (0.3 kgf-m, 2.2 ft-lb)
(A) (B) (A) (B)
IN-02266
C: INSPECTION
IN-02266
5) Remove the air cleaner case (rear) and air cleaner element.
1) Replace if excessively damaged or dirty. 2) Replace the air cleaner case (rear) when the HC adsorption filter is damaged. (U5 model and C5 model)
IN-02192
IN(H4SO)-4
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case

A: REMOVAL
6) Remove the air intake duct. <Ref. to IN(H4SO)8, REMOVAL, Air Intake Duct.> 7) Remove the bolts (A) and nut (B) which secure the air cleaner case to body.
(B)
(A)
IN-00203
IN-02216
8) Remove the air cleaner case (front).
IN-02264
(A) (B)
IN-02266
IN-02192
IN(H4SO)-5
Air Cleaner Case

INTAKE (INDUCTION)
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Bolt (A) 6 Nm (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
(B)
(A)
IN-02216
NOTE: When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.
IN-02191
Tightening torque: Clamp (A): 3 Nm (0.3 kgf-m, 2.2 ft-lb)
(A) (B)
IN-02266
C: INSPECTION
Check for cracks or loose connections.
IN(H4SO)-6
Air Intake Chamber

INTAKE (INDUCTION)
4. Air Intake Chamber

A: REMOVAL
1) Loosen the clamp (A) which connects air intake chamber to throttle body. 2) Loosen the clamp (B) which connects intake boot to air intake chamber. 3) Remove the bolt (C) which secures air intake chamber to the stay. 4) Disconnect the connector (D).
(B) (C) (D) (A)
(C)
IN-02141
5) Disconnect the blow-by hoses, and then remove air intake chamber.
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Clamp (A), (B) 3 Nm (0.3 kgf-m, 2.2 ft-lb) Bolt (C) 6.5 Nm (0.7 kgf-m, 4.8 ft-lb)
(B) (C) (A)
(C)
IN-02142
C: INSPECTION
1) Check for cracks or loose connections. 2) Inspect that no foreign objects are mixed in the air intake chamber.
IN(H4SO)-7
Air Intake Duct

INTAKE (INDUCTION)
5. Air Intake Duct

A: REMOVAL
1) Remove the clip which installs the air intake duct on the front side of body. 2) Remove the air intake duct.
IN-02082
B: INSTALLATION
C: INSPECTION
1) Check for cracks or loose connections. 2) Check that no foreign matter is mixed in air intake duct.
IN(H4SO)-8
Resonator Chamber
INTAKE (INDUCTION)
6. Resonator Chamber
A: REMOVAL
The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to Air Cleaner Case for removal procedure. <Ref. to IN(H4SO)-5, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to Air Cleaner Case for installation procedure. <Ref. to IN(H4SO)-6, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H4SO)-9
Resonator Chamber
INTAKE (INDUCTION)
IN(H4SO)-10
General Description
MECHANICAL
A: SPECIFICATION
Model Cylinder arrangement Valve system mechanism Bore Stroke Displacement Compression ratio Compression pressure (at 200 300 rpm) Number of piston rings 2.5 L Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Belt driven Single overhead camshaft 4 valve/cylinder mm (in) 99.5 79.0 (3.917 3.110) 2,457 (150) cm3 (cu in) 10.0 kPa (kg/cm2, psi) 1,020 1,275 (10.4 13.0, 148 185) Pressure ring: 2, Oil ring: 1 BTDC 0 ABDC 58 BTDC 0 ABDC 10 BTDC 14 ABDC 62 BBDC 30 ATDC 14 0.20r0.04 (0.0079r0.0016) 0.25r0.04 (0.0098r0.0016) 650r100 (No load) 850r100 (A/C ON) 700r100 (No load) 850r100 (A/C ON) 1o3o2o4 10r8/650 15r10/700
Engine
Intake valve timing
Exhaust valve timing Valve clearance
Open Constant Close Open Low speed Close Open High speed Close Open Close mm (in) Intake Exhaust MT rpm AT
Idling speed [at neutral position on MT, or P or N position on AT] Ignition order Ignition timing
BTDC/rpm
MT AT
ME(H4SO)-2
General Description
MECHANICAL
NOTE: US: Undersize OS: Oversize

Belt tension adjuster Valve rocker arm Protrusion of adjuster rod Clearance between shaft and arm Bending limit Thrust clearance Intake mm (in) mm (in) Standard mm (in) Standard Standard Standard Standard Standard mm (in) mm (in) mm (in) Standard mm (in) mm (in) mm (in) Intake Exhaust 5.2 6.2 (0.205 0.244) 0.020 0.054 (0.0008 0.0021) 0.025 (0.00098) or less 0.030 0.090 (0.0012 0.0035) 40.075 40.175 (1.5778 1.5817) 35.496 35.596 (1.3975 1.4014) 40.315 40.415 (1.5872 1.5911) 39.289 39.389 (1.5468 1.5507) 31.928 31.945 (1.2570 1.2577) 32.000 32.018 (1.2598 1.2605) 0.055 0.090 (0.0022 0.0035) 0.035 (0.0014) 0.1 (0.004) 97.5 (3.84) 90 0.8 1.4 (0.03 0.055) 1.2 1.8 (0.047 0.071) 6.000 6.012 (0.2362 0.2367) 20.0 21.0 (0.787 0.827) 16.5 17.5 (0.650 0.689) 0.8 1.2 (0.03 0.047) 1.0 1.4 (0.039 0.055) 5.950 5.965 (0.2343 0.2348) 5.945 5.960 (0.2341 0.2346) 0.035 0.062 (0.0014 0.0024) 0.040 0.067 (0.0016 0.0026) 120.6 (4.75) 121.7 (4.79) 55.2 (2.173) 2.5, 2.4 (0.094) or less 235.3 270.7 (24 27.6, 52.9 60.8) /45.0 (1.772) 578.9 639.9 (59.1 65.3, 130.3 143.9) /34.7 (1.366) 0.025 (0.00098) 0.1 (0.004) 201.0 (7.91) 99.505 99.515 (3.9175 3.9179) 99.495 99.505 (3.9171 3.9175) 0.015 (0.0006) 0.010 (0.0004) 0.010 0.010 (0.00039 0.00039) To 100.005 (3.9372) 99.505 99.515 (3.9175 3.9179) 99.495 99.505 (3.9171 3.9175) 99.745 99.765 (3.9270 3.9277) 99.995 100.015 (3.9368 3.9376)
Camshaft
Cam lobe height
mm (in)
mm (in) Constant Low speed High speed
Cylinder head
Exhaust Camshaft journal O.D. Camshaft journal hole I.D. Oil clearance Surface warping limit (Mating surface with cylinder block) Grinding limit Standard height Seating angle Contacting width Inside diameter mm (in)
Valve seat
Valve guide
Protrusion above head Head edge thickness Stem outer diameter
Valve Valve stem gap Overall length Free length Squareness Valve spring Tension/spring height
Standard Standard mm (in) Intake mm (in) Exhaust Intake Standard mm (in) Exhaust Standard Intake mm (in) Exhaust Intake mm (in) Standard Exhaust Intake mm (in) Exhaust mm (in)
Set N (kgf, lb)/mm (in) Lift Surface warping limit (mating with cylinder head) Grinding limit Standard height mm (in) mm (in) mm (in) mm (in) Standard
Cylinder block
Piston
A B Taper mm (in) Standard Out-of-roundness mm (in) Standard Piston clearance mm (in) Standard Cylinder inner diameter boring limit (diameter) mm (in) A Standard B Outer diameter mm (in) 0.25 (0.0098) OS 0.50 (0.0197) OS Cylinder inner diameter
ME(H4SO)-3
General Description
MECHANICAL
Standard clearance between piston and piston pin Degree of fit Top ring Ring closed gap mm (in) Second ring Oil ring Top ring Ring groove gap mm (in) Second ring Bend or twist per 100 mm (3.94 in) mm (in) in length Thrust clearance Oil clearance Bearing size (Thickness at center) Standard Standard Standard Standard Standard mm (in) Standard 0.004 0.008 (0.0002 0.0003) Piston pin must be fitted into position with thumb at 20C (68F). 0.20 0.35 (0.0079 0.0138) 0.37 0.52 (0.0146 0.0205) 0.20 0.50 (0.0079 0.0197) 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028) 0.10 (0.0039) 0.070 0.330 (0.0028 0.0130) 0.016 0.044 (0.0006 0.0017) 1.492 1.501 (0.0587 0.0591) 1.510 1.513 (0.0594 0.0596) 1.520 1.523 (0.0598 0.0600) 1.620 1.623 (0.0638 0.0639) 0 0.022 (0 0.0009) 0.035 (0.0014) 0.003 (0.0001) 0.004 (0.0002) To 51.750 (2.0374) 0.005 (0.0002) 0.006 (0.0002) To 59.758 (2.3527) 51.984 52.000 (2.0466 2.0472) 51.954 51.970 (2.0454 2.0461) 51.934 51.950 (2.0446 2.0453) 51.734 51.750 (2.0368 2.0374) 59.992 60.008 (2.3619 2.3625) 59.962 59.978 (2.3607 2.3613) 59.942 59.958 (2.3599 2.3605) 59.742 59.758 (2.3520 2.3527) 0.030 0.115 (0.0012 0.0045) 0.010 0.030 (0.0004 0.0012) 1.998 2.011 (0.0787 0.0792) 2.017 2.020 (0.0794 0.0795) 2.027 2.030 (0.0798 0.0799) 2.127 2.130 (0.0837 0.0839) 2.000 2.013 (0.0787 0.0793) 2.019 2.022 (0.0795 0.0796) 2.029 2.032 (0.0799 0.0800) 2.129 2.132 (0.0838 0.0839)
Piston pin
Piston ring
Connecting rod
Bearing of large end
Service limit mm (in) Standard mm (in) Standard Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Standard
Bushing of small end
Clearance between piston pin and bushing mm (in) Bending limit
Crankshaft
Main bearing
mm (in) Out-of-roundness mm (in) Crank pin Cylindricality mm (in) Grinding limit (dia.) mm (in) Out-of-roundness mm (in) Crank journal Cylindricality mm (in) Grinding limit (dia.) mm (in) Standard 0.03 (0.0012) US Crank pin outer diameter mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Standard 0.03 (0.0012) US Crank journal outer diameter mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Thrust clearance mm (in) Standard Oil clearance mm (in) Standard Standard 0.03 (0.0012) US #1, #3 0.05 (0.0020) US Bearing size 0.25 (0.0098) US (Thickness at center) Standard mm (in) #2, #4, 0.03 (0.0012) US #5 0.05 (0.0020) US 0.25 (0.0098) US
ME(H4SO)-4
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(5)
T1
(1) (2) T2
T5
(3) (6) T4 (8) (7)
(4)
(12)
T1 T3
T1 T4 T4 (9) T1
(10)
(15)
(13) T5
(11)
(16) (14)
T6
T1 T6 ME-03954
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Timing belt cover No. 2 RH Timing belt guide (MT model) Crank sprocket Timing belt cover No. 2 LH Cam sprocket No. 1 Belt idler (A) Tensioner bracket Belt idler (B) Automatic belt tension adjuster ASSY
(10) (11) (12) (13) (14) (15) (16)
Belt idler No. 2 Cam sprocket No. 2 Timing belt Front timing belt cover Timing belt cover LH Crank pulley (MT model) Crank pulley (AT model)
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 9.75 (1.0, 7.2) T3: 24.5 (2.5, 18.1) T4: 39 (4.0, 28.8) T5: 78 (8.0, 57.5) T6: <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.>
ME(H4SO)-5
General Description
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT

(1) (20) (2) T2 T4 T3 T10 (4) (26) T7 (22) T11 (25) T8
(7) T5 (3) (8) T3 (24) (6) (8) (23)
(5)
T1 (9) (10) (30) T10 (19) (8) (14) (15) T1 (16) (7) T6 T4 (29) (11) T3 (21) (19) (12) (5) (13) T4 (31) T3 (3) T5 ME-03453 T9 T5 (2) (17) (18)
(10) T8
(28) (27)
T7
T2
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)
Rocker cover RH Intake valve rocker ASSY Exhaust valve rocker ASSY Camshaft cap RH Oil seal Camshaft RH Plug Spark plug pipe gasket Cylinder head RH Cylinder head gasket Cylinder head LH Camshaft LH Camshaft cap LH Oil filler cap Gasket Oil filler duct O-ring
(18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)
Rocker cover LH Stud bolt Rocker cover gasket RH Rocker cover gasket LH Oil switching solenoid valve RH Oil switching solenoid valve holder RH Gasket Oil temperature sensor Variable valve lift diagnosis oil pressure switch RH Oil switching solenoid valve LH Oil switching solenoid valve holder LH Gasket Variable valve lift diagnosis oil pressure switch LH
(31)
Seal washer
Tightening torque:Nm (kgf-m, ft-lb) T1: <Ref. to ME(H4SO)-59, INSTALLATION, Cylinder Head.> T2: <Ref. to ME(H4SO)-52, INSTALLATION, Valve Rocker Assembly.> T3: T4: T5: T6: T7: T8: T9: T10: T11: 9.75 (1.0, 7.2) 18 (1.8, 13.3) 25 (2.5, 18.4) 6.4 (0.7, 4.7) 8 (0.8, 5.9) 10 (1.0, 7.4) 6 (0.6, 4.4) 17 (1.7, 12.5) 18 (1.8, 13.3)
ME(H4SO)-6
General Description
MECHANICAL
3. VALVE ROCKER ASSEMBLY
T2
T3
(1)
(1)
T1
(5) (2)
(2) (4) T2 (3)
T2
(3)
T3
ME-02691
(1) (2) (3)
Intake valve rocker ASSY Valve rocker nut Valve rocker adjusting screw
(4) (5)
Exhaust rocker shaft Exhaust valve rocker arm
Tightening torque:Nm (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 9.75 (1.0, 7.2) T3: 25 (2.5, 18.4)
ME(H4SO)-7
General Description
MECHANICAL
4. CYLINDER HEAD AND VALVE ASSEMBLY
(1)
(1)
(3)
(4)
(5)
(6)
(7)
(8)
(2) (2)
(3) (4) (9) (6) (7) (8)
ME-03322
(1) (2) (3)
Exhaust valve Intake valve Valve guide
(4) (5) (6)
Valve spring seat Intake valve oil seal Valve spring
(7) (8) (9)
Retainer Retainer key Exhaust valve oil seal
ME(H4SO)-8
General Description
MECHANICAL
5. CYLINDER BLOCK
T6 (31) T2 T2
T4
(1) (7) T5
(5)
(32)
(28) (29) (2) (4) (28) (3) T4 (6)
T2 (32) (8) (10)
T10
T2 (11) T2
(9) (4) T2 (14) (15) (10) T9 T10 T2 (23) (10) (16) T2 T3 (17) T7 T2 (24) T2 (22) (26) (4) (27)
(10)
(3) T4
(28)
T10 (3) (12)
(29)
T4
T5
(13) (25)
T1
(30) (21) (18) (20) (19) T8
ME-03563
ME(H4SO)-9
General Description
MECHANICAL
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) Oil pressure switch Cylinder block RH Service hole plug Gasket Oil separator cover Water by-pass pipe Oil pump Front oil seal Rear oil seal O-ring Service hole cover Cylinder block LH Water pump Baffle plate Oil filter connector Oil strainer (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) Gasket Oil pan Drain plug Drain plug gasket Oil level gauge guide Water pump sealing Oil filter Gasket Water pump hose Plug Seal Seal washer Washer O-ring Engine rear hanger (32) Oil pump seal
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 6.4 (0.7, 4.7) T3: 10 (1.0, 7.4) T4: 25 (2.5, 18.4) T5: <Ref. to ME(H4SO)-71, INSTALLATION, Cylinder Block.> T6: 16 (1.6, 11.8) T7: First 12 (1.2, 8.9) Second 12 (1.2, 8.9) T8: 44 (4.5, 32.5) T9: 45 (4.6, 33.2) T10: 70 (7.1, 51.6)
ME(H4SO)-10
General Description
MECHANICAL
6. CRANKSHAFT AND PISTON
(1) T2
(2)
(4)
T2 (10) (5) (6) (7) (10) (8) (11) (14) (13) (9) (12) (3)
T1
(15) (13) (14) (11) (13) T1
(8) (16) (13)
(10) (7) (6) (5)
(12) (10)
(9) (19) (18) (17) (18) (17) ME-03549
(1) (2) (3) (4) (5) (6) (7) (8)
Flywheel (MT model) Ball bearing (MT model) Reinforcement (AT model) Drive plate (AT model) Top ring Second ring Oil ring Piston
(9) (10) (11) (12) (13) (14) (15) (16)
Piston pin Snap ring Connecting rod nut Connecting rod Connecting rod bearing Connecting rod cap Crankshaft Woodruff key
(17) (18) (19)
Crankshaft bearing #1, #3 Crankshaft bearing #2, #4 Crankshaft bearing #5
Tightening torque:Nm (kgf-m, ft-lb) T1: 45 (4.6, 33.2) T2: 72 (7.3, 53.1)
ME(H4SO)-11
General Description
MECHANICAL
7. ENGINE MOUNTING
(1)
T1
T2
T1
T2
ME-02090
(1)
Front cushion rubber
ME(H4SO)-12
General Description
MECHANICAL
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel. All removed parts, if to be reused, should be reinstalled in the original positions and directions. Bolts, nuts and washers should be replaced with new parts as required. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. Lift up or lower the vehicle when necessary. Make sure to support the correct positions.
ME(H4SO)-13
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 18231AA010 DESCRIPTION CAM SPROCKET WRENCH REMARKS Used for removing and installing cam sprocket. CAM SPROCKET WRENCH (499207100) can also be used.
ST18231AA010
1B022XU0
Used for troubleshooting the electrical system.
ST1B022XU0
498267800
CYLINDER HEAD TABLE
Used for replacing valve guides. Used for removing and installing valve spring.
ST-498267800
498277200
STOPPER SET
Used for installing automatic transmission assembly to engine.
ST-498277200
ME(H4SO)-14
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 498457000 DESCRIPTION ENGINE STAND ADAPTER RH REMARKS Used together with the ENGINE STAND (499817100).
ST-498457000
498457100
ENGINE STAND ADAPTER LH
Used together with the ENGINE STAND (499817100).
ST-498457100
498497100
CRANKSHAFT STOPPER
Used for removing and installing flywheel and drive plate.
ST-498497100
498747300
PISTON GUIDE
Used for installing piston in cylinder.
ST-498747300
498857100
VALVE OIL SEAL GUIDE
Used for press-fitting of intake and exhaust valve guide oil seals.
ST-498857100
ME(H4SO)-15
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499017100 DESCRIPTION PISTON PIN GUIDE REMARKS Used for installing piston pin, piston and connecting rod.
ST-499017100
499037100
CONNECTING ROD BUSHING REMOVER AND INSTALLER
Used for removing and installing connecting rod bushing.
ST-499037100
499587200
CRANKSHAFT OIL SEAL INSTALLER
Used for installing crankshaft oil seal. Used together with the CRANKSHAFT OIL SEAL GUIDE (499597100).
ST-499587200
499587500
OIL SEAL INSTALLER
Used for installing camshaft oil seal. Used together with the OIL SEAL GUIDE (499597000).
ST-499587500
499587700
CAMSHAFT OIL SEAL INSTALLER
Used for installing cylinder head plug.
ST-499587700
ME(H4SO)-16
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499097700 DESCRIPTION PISTON PIN REMOVER ASSY REMARKS Used for removing piston pin.
ST-499097700
499497000
TORX PLUS
Used for removing and installing camshaft cap.
ST-499497000
499587100
OIL SEAL INSTALLER
Used for installing oil pump oil seal.
ST-499587100
499597000
OIL SEAL GUIDE
Used for installing camshaft oil seal. Used together with the OIL SEAL INSTALLER (499587500).
ST-499597000
499597100
CRANKSHAFT OIL SEAL GUIDE
Used for installing crankshaft oil seal. Used together with the CRANKSHAFT OIL SEAL INSTALLER (499587200).
ST-499597100
ME(H4SO)-17
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499718000 DESCRIPTION VALVE SPRING REMOVER REMARKS Used for removing and installing valve spring.
ST-499718000
499767200
VALVE GUIDE REMOVER
Used for removing valve guides.
ST-499767200
499767400
VALVE GUIDE REAMER
Used for reaming valve guides.
ST-499767400
499767700
VALVE GUIDE ADJUSTER
Used for installing valve guides. (Intake side)
ST-499767700
499767800
Used for installing valve guides. (Exhaust side)
ST-499767800
ME(H4SO)-18
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499817100 DESCRIPTION ENGINE STAND REMARKS Stand used for engine disassembly and assembly. Used together with the ENGINE STAND ADAPTER RH (498457000) & LH (498457100).
ST-499817100
499977100
CRANK PULLEY WRENCH
Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (MT model)
ST-499977100
499977400
CRANK PULLEY WRENCH
Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (AT model)
ST-499977400
499987500
CRANKSHAFT SOCKET
Used for rotating crankshaft.
ST-499987500
42099AE000
QUICK CONNECTOR RELEASE
Used for disconnecting quick connector in the engine compartment.
ST42099AE000
ME(H4SO)-19
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 18354AA000 DESCRIPTION VALVE ROCKER HOLDER REMARKS Used for installing the valve rocker assembly (intake). (2-piece set)
ST18354AA000
18258AA000
SPRING INSTALLER
Used for installing the valve rocker assembly (intake).
ST18258AA000
2. GENERAL TOOL
TOOL NAME Compression gauge Vacuum gauge Oil pressure gauge Fuel pressure gauge Timing light REMARKS Used for measuring compression. Used for measuring intake manifold vacuum. Used for measuring engine oil pressure. Used for measuring fuel pressure. Used for measuring ignition timing.
E: PROCEDURE
It is possible to conduct the following service procedures with engine on vehicle, however, the procedures described in this section are based on the condition that the engine is removed from vehicle. V-belt Timing belt Valve rocker ASSY Camshaft Cylinder head
ME(H4SO)-20
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) After warming-up the engine, turn the ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 4) Remove all the spark plugs. <Ref. to IG(H4SO)4, REMOVAL, Spark Plug.> 5) Fully open the throttle valve. 6) Check the starter motor for satisfactory performance and operation. 7) Secure the compression gauge tightly against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long. 8) Crank the engine by the starter motor, and read the maximum value on the gauge when the needle of gauge is steady.
ME-00192
9) Perform at least two measurements per cylinder, and check that the values are correct. Compression (fully open throttle): Standard 1,020 1,275 kPa (10.4 13.0 kgf/cm2, 148 185 psi) Difference between cylinders 49 kPa (0.5 kgf/cm2, 7 psi) or less 10) After inspection, install the related parts in the reverse order of removal.
ME(H4SO)-21
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the following item: (1) Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the engine idle speed using Subaru Select Monitor. <Ref. to EN(H4SO)(diag)-34, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> 4) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF) Idle speed [No load and gear in neutral, or P, N range]: 650r100 rpm (MT model) 700r100 rpm (AT model) 5) Check the idle speed when loaded. (Turn the A/C switch to ON and operate the compressor for at least one minute before measurement.) Idle speed [A/C ON and gear in neutral or P or N range]: 850r100 rpm NOTE: Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to the General On-board Diagnosis Table under Engine Control System. <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>
ME(H4SO)-22
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement. 1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Stop the engine, and turn the ignition switch to OFF. 4) Connect the timing light to #1 cylinder spark plug cord, and then light the timing mark with the timing light. 5) Start the engine and check the ignition timing at idle speed as shown below. Ignition timing [BTDC/rpm]: 10r8/650 (MT model) 15r8/700 (AT model)
20
10
ME-02676
If the timing is not correct, check the ignition control system. <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>
ME(H4SO)-23
Intake Manifold Vacuum

MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
1) Warm up the engine. 2) Disconnect the brake booster vacuum hose from the intake manifold, and then install the vacuum gauge. 3) Keep the engine at idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below.
ME-02694
Vacuum pressure (at idling, A/C OFF): Less than 60.0 kPa (450 mmHg, 17.72 inHg)
Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than normal position. This tendency Air leakage around intake manifold gasket, disconnection becomes more evident as engine temperature rises. or damage of vacuum hose 2. Needle intermittently drops to position lower than normal position. Leakage around cylinder 3. Needle drops suddenly and intermittently from normal position. Sticky valve 4. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 5. Needle vibrates above and below normal position in narrow range. Defective ignition system
ME(H4SO)-24
Engine Oil Pressure

MECHANICAL
6. Engine Oil Pressure

A: INSPECTION
1) Disconnect the ground cable from the battery.
5) Start the engine, and measure the oil pressure.
ME-03698
Oil pressure:
IN-00203
2) Remove the oil pressure switch. <Ref. to LU(H4SO)-20, REMOVAL, Oil Pressure Switch.> 3) Connect the oil pressure gauge to cylinder block. 4) Connect the ground cable to battery.
Standard 98 kPa (1.0 kg/cm2, 14 psi) or more at 600 rpm 294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000 rpm If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. <Ref. to LU(H4SO)-24, INSPECTION, Engine Lubrication System Trouble in General.> If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. <Ref. to LU(H4SO)-24, INSPECTION, Engine Lubrication System Trouble in General.> NOTE: Standard value is based on an engine oil temperature of 80C (176F). 6) After measuring the oil pressure, install the oil pressure switch. <Ref. to LU(H4SO)-20, INSTALLATION, Oil Pressure Switch.>
IN-00203
ME(H4SO)-25
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
CAUTION: Before removing the fuel pressure gauge, release the fuel pressure. Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. NOTE: Check or replace the fuel pump and fuel delivery line if the fuel pressure is out of the standard. 1) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Open the fuel filler lid, and remove the fuel filler cap. 3) Disconnect the fuel delivery hose from the fuel damper, and connect the fuel pressure gauge.
ME-03054
4) Start the engine. 5) Measure the fuel pressure after warming up the engine. NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kg/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Fuel pressure: Standard: 338 348 kPa (3.4 3.5 kg/cm2, 49 50 psi)
ME(H4SO)-26
Valve Clearance
MECHANICAL
8. Valve Clearance
A: INSPECTION
NOTE: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Lower the vehicle. 5) Disconnect the ground cable from the battery.
10) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the arrow mark (A) on cam sprocket LH is at the top position, the #1 cylinder piston is at top dead center of the compression stroke.
(A)
ME-00200
11) Measure #1 cylinder valve clearance by using thickness gauge (A).

IN-00203
6) Remove the timing belt cover LH.
NOTE: Insert the thickness gauge (A) in as horizontally as possible with respect to the valve stem end face. Lift up the vehicle, and then measure the exhaust valve clearances. Valve clearance: Intake 0.20r0.04 mm (0.0079r0.0016 in) Exhaust 0.25r0.04 mm (0.0098r0.0016 in)
(A)
ME-00199
7) Remove the fuel injector. <Ref. to FU(H4SO)30, REMOVAL, Fuel Injector.> 8) When inspecting #1 and #3 cylinders (1) Disconnect the spark plug cords from spark plugs RH side. <Ref. to IG(H4SO)-4, RH SIDE, REMOVAL, Spark Plug.> (2) Place a suitable container under the vehicle. (3) Disconnect the PCV hose from the rocker cover RH. (4) Remove the bolts, then remove the rocker cover RH. 9) When inspecting #2 and #4 cylinders (1) Disconnect the spark plug cords from spark plugs on LH side. <Ref. to IG(H4SO)-4, LH SIDE, REMOVAL, Spark Plug.> (2) Place a suitable container under the vehicle. (3) Disconnect the PCV hose from the rocker cover LH. (4) Remove the bolts, then remove the rocker cover LH.
ME-02696
12) If necessary, adjust the valve clearance. <Ref. to ME(H4SO)-28, ADJUSTMENT, Valve Clearance.>
ME(H4SO)-27
Valve Clearance
MECHANICAL
13) Measure the valve clearance in #3, #2 and #4 cylinder in the same measurement procedure as #1 cylinder in this order. NOTE: Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before measuring valve clearances. By rotating the crank pulley clockwise every 180 from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order. 14) After inspection, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.
2) Adjust the #1 cylinder valve clearance. (1) Loosen the valve rocker nut and screw. (2) Set a suitable thickness gauge. (3) While noting the valve clearance, tighten the valve rocker adjusting screw. (4) When the specified valve clearance is obtained, tighten the valve rocker nut. NOTE: Insert a thickness gauge in a direction as horizontal as possible with respect to the valve stem end face. Lift up the vehicle and adjust the exhaust valve clearances. Valve clearance: Intake 0.20r0.04 mm (0.0079r0.0016 in) Exhaust 0.25r0.04 mm (0.0098r0.0016 in) Tightening torque: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
B: ADJUSTMENT
NOTE: Adjustment of valve clearance should be performed while engine is cold. 1) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the arrow mark (A) on cam sprocket LH is at the top position, the #1 cylinder piston is at top dead center of the compression stroke.
(A)
ME-00203
3) Adjust the valve clearance in #3, #2 and #4 cylinder in the same adjustment procedure as #1 cylinder in this order. NOTE: Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. By rotating the crank pulley clockwise every 180 from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order. 4) Ensure the valve clearances of each cylinder are within specifications. If necessary, readjust the valve clearances.
ME-00200
ME(H4SO)-28
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift. 2) Open the front hood fully and support with the front hood stay. 3) Remove the V-belt covers.
12) Disconnect the following connectors and cables. (1) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) and remove the clip (C) fastening the harness.
(B) (A)
(C)
EX-02350
ME-03945
4) Collect the refrigerant from A/C system. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 5) Release the fuel pressure. <Ref. to FU(H4SO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 6) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 7) Remove the air intake duct, air cleaner case and air intake chamber. <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Duct.> <Ref. to IN(H4SO)-5, REMOVAL, Air Cleaner Case.> <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 8) Remove the under cover. 9) Remove the radiator from vehicle. <Ref. to CO(H4SO)-19, REMOVAL, Radiator.> 10) Disconnect the A/C pressure hoses from A/C compressor. 11) Remove the air intake chamber stay.
(2) Remove the bolt, and disconnect the engine harness connector from the bulk head harness connector and rear engine hanger.
FU-03924
(3) Generator connector and terminal

(A)
(B) ME-00818
(A) Terminals (B) Generator connector
(4) A/C compressor connector

ME-00816
ME-00819
ME(H4SO)-29
Engine Assembly
MECHANICAL
(5) Power steering pump switch connector
17) Disconnect the ground cable on the engine side.
ME-03004
13) Disconnect the following hoses. (1) Brake booster vacuum hose
ME-03376
ME-03377
ME-02698
(2) Heater inlet and outlet hoses 14) Remove the power steering pump. (1) Remove the front side belts. <Ref. to ME(H4SO)-38, FRONT SIDE BELT, REMOVAL, V-belt.> (2) Remove the bolts which secure the power steering pump to the bracket.
18) Remove the bolts and nuts which hold lower side of transmission to engine. AT model
AT-00108
MT model
ME-00037
(3) Place the power steering pump on the right side wheel apron. 15) Lift up the vehicle. 16) Remove the front and center exhaust pipes. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.>
MT-00077
ME(H4SO)-30
Engine Assembly
MECHANICAL
19) Remove the nuts which hold the engine mount to the front crossmember.
22) Disconnect the fuel delivery hose from the fuel pipe. (1) Disconnect the quick connector on the fuel delivery line by pushing the ST in the direction of the arrow. ST 42099AE000 QUICK CONNECTOR RELEASE (2) Remove the clip and disconnect the evaporation hose from the pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
LU-02470
20) Separate the torque converter clutch from drive plate. (AT model) (1) Lower the vehicle. (2) Remove the service hole plug. (3) Insert the wrench into the crank pulley bolt and rotate the crank pulley to remove the bolts which hold torque converter clutch to drive plate.
(A)
(B)
FU-02715
(A) Fuel delivery hose (B) Evaporation hose
23) Support the engine with a lifting device and wire ropes.
ME-00212
21) Remove the pitching stopper.
LU-00222
AT-03877
ME(H4SO)-31
Engine Assembly
MECHANICAL
24) Support the transmission with a garage jack. CAUTION: Be sure to always perform this work, in order to prevent the transmission from lowering for its own weight.
(3) Remove the bolts which hold upper side of transmission to engine. AT model
(A) (B)
AT-00106
MT model
ME-00215
(A) Transmission (B) Garage jack
25) Separation of engine and transmission CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. (1) Remove the starter. <Ref. to SC(H4SO)-6, REMOVAL, Starter.> (2) Attach the ST to the torque converter clutch case. (AT model) ST 498277200 STOPPER SET
MT-01524
26) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. (3) Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model) (4) Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 27) Remove the engine mounting from the engine.
ST ME-00217
ME(H4SO)-32
Engine Assembly
MECHANICAL
B: INSTALLATION
1) Install the engine mounting onto the engine. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb) 2) Apply a small amount of grease to splines of main shaft. (MT model) Grease: NICHIMOLY N-130 or equivalent 3) Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 4) Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) AT model
7) Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
T1
T2
AT-03878
8) Remove the ST from the torque converter clutch case. (AT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET
AT-00106
ST ME-00217
MT model
9) Install the starter. <Ref. to SC(H4SO)-6, INSTALLATION, Starter.> 10) Install the torque converter clutch to drive plate. (AT model) (1) Insert the wrench into the crank pulley bolt and rotate the crank pulley to tighten the bolts which hold torque converter clutch to drive plate. NOTE: Be careful not to drop bolts into the torque converter clutch case. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-01524
5) Remove the lifting device and wire ropes.
LU-00222
6) Remove the garage jack.
ME-00212
(2) Install the service hole plug.
ME(H4SO)-33
Engine Assembly
MECHANICAL
11) Install the power steering pump. (1) Install the power steering pump. Tightening torque: Refer to COMPONENT of Power Steering for the tightening torque. <Ref. to PS-3, COMPONENT, General Description.>
MT model
MT-00077
14) Tighten the nuts which hold the engine mount to the crossmember. Tightening torque: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
ME-00037
(2) Connect the power steering pump switch connector.
LU-02470
15) Connect the ground cable.

ME-03004
(3) Install and adjust the front side belt. <Ref. to ME(H4SO)-39, FRONT SIDE BELT, INSTALLATION, V-belt.> 12) Lift up the vehicle. 13) Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) AT model
ME-03376
AT-00108 ME-03377
16) Install the front and center exhaust pipe. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> 17) Lower the vehicle.
ME(H4SO)-34
Engine Assembly
MECHANICAL
18) Connect the following hoses. (1) Fuel delivery hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose 19) Connect the following connectors and terminals. (1) Front oxygen (A/F) sensor connector (2) Rear oxygen sensor connector (3) Engine harness connectors Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
29) Install the V-belt cover. Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
ME-03945
30) Remove the front hood stay, and close the front hood. 31) Lower the vehicle from lift.
C: INSPECTION
FU-03924
(4) Generator connector and terminal Tightening torque: 15 Nm (1.5 kgf-m, 11.1 ft-lb) (5) A/C compressor connector 20) Install the air intake chamber stay. Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb) 21) Install the A/C pressure hoses. <Ref. to AC-40, INSTALLATION, Hose and Pipe.> 22) Install the radiator to vehicle. <Ref. to CO(H4SO)-20, INSTALLATION, Radiator.> 23) Install the air intake duct, air cleaner case and air intake chamber. <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4SO)-6, INSTALLATION, Air Cleaner Case.> <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 24) Install the under cover. 25) Install the battery. <Ref. to SC(H4SO)-20, INSTALLATION, Battery.> 26) Fill engine coolant. <Ref. to CO(H4SO)-13, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 27) Check the ATF level and replenish it if necessary. (AT model) <Ref. to 4AT-26, INSPECTION, Automatic Transmission Fluid.> 28) Charge the A/C system with refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.>
1) Check that pipes, hoses, connectors and clamps are installed firmly. 2) Check the engine coolant is at specified level. 3) Check the ATF is at specified level. (AT model) 4) Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.
ME(H4SO)-35
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H4SO)-29, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Engine mounting 35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that no crack or other damages do not exist.
ME(H4SO)-36
Preparation for Overhaul

MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from body, secure it to ST in the following procedure. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND
ST3
ST2
ST1 ME-00221
2) In this section the procedures described under each index are all connected and stated in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.
ME(H4SO)-37
V-belt
MECHANICAL
12.V-belt
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body.
2. REAR SIDE BELT

1) Remove the front side belts. <Ref. to ME(H4SO)-38, FRONT SIDE BELT, REMOVAL, V-belt.> 2) Loosen the lock nut (A). 3) Loosen the slider bolt (B).
(B)
1. FRONT SIDE BELT

1) Remove the V-belt covers.
(A)
ME-00224
ME-03945
4) Remove the rear side belt. 5) Remove the belt tensioner.
2) Loosen the bolt (A). 3) Loosen the slider bolt (B). 4) Remove the front side belt (C).
(C)
(B)
ME-00225
(A)
ME-02699
ME(H4SO)-38
V-belt
MECHANICAL
B: INSTALLATION
1. FRONT SIDE BELT
CAUTION: When reusing the front side belt, wipe off dust and water with cloth. Do not use the front side belt if there is any oil, grease or coolant on the belt. Be careful not to rub the belt end surface with bare hands; exposed core may cause injury. 1) Wipe off any dust, oil and water on the groove of each pulley with cloth. 2) Install the front side belt (C), and adjust the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(H4SO)-40, INSPECTION, V-belt.> 3) Tighten the bolt (A). 4) Tighten the slider bolt (B). Tightening torque: Bolt (A) 25 Nm (2.5 kgf-m, 18.4 ft-lb) Slider bolt (B) 8 Nm (0.8 kgf-m, 5.9 ft-lb)
2. REAR SIDE BELT

CAUTION: When reusing the rear side belt, wipe off dust and water with cloth. Do not use the rear side belt if there is any oil, grease or coolant on the belt. Be careful not to rub the belt end surface with bare hands; exposed core may cause injury. 1) Wipe off any dust, oil and water on the groove of each pulley with cloth. 2) Install the belt tensioner. 3) Install the rear side belt, and adjust the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(H4SO)-40, INSPECTION, V-belt.> 4) Tighten the lock nut (A). Tightening torque: Lock nut (A) 23 Nm (2.3 kgf-m, 17.0 ft-lb)
(B)
(A) (C) (B)
ME-00224
(A)
ME-02699
5) Install the front side belt. <Ref. to ME(H4SO)-39, FRONT SIDE BELT, INSTALLATION, V-belt.>
5) Install the V-belt cover. Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
ME-03945
ME(H4SO)-39
V-belt
MECHANICAL
C: INSPECTION
1) Replace the belts, if crack, fraying or wear is found. 2) Check the belt tension and adjust it if necessary by changing the generator installing position or idler pulley installing position. Belt tension (with belt tension gauge): (A) When installing new parts: 640 780 N (65 80 kgf, 144 175 lb) At inspection: 490 640 N (50 65 kgf, 110 144 lb) (B) When installing new parts: 650 750 N (66 76 kgf, 146 169 lb) At inspection: 350 450 N (36 46 kgf, 78 101 lb)
(A)
Belt tension (without belt tension gauge): (A) When installing new parts: 7 9 mm (0.276 0.354 in) At inspection: 9 11 mm (0.354 0.433 in) (B) When installing new parts: 7.5 8.5 mm (0.295 0.335 in) At inspection: 9.0 10.0 mm (0.354 0.394 in)
(C) GEN A/C
P/S
(A) (B)
I/P C/P GEN A/C (B)
P/S
ME-00226
I/P C/P PM-00154
Front side belt Rear side belt Crank pulley Generator pulley Power steering oil pump pulley A/C compressor pulley Idler pulley
(A) (B) (C) C/P GEN P/S A/C I/P
Front side belt Rear side belt 98 N (10 kg, 22 lbf) Crank pulley Generator pulley Power steering oil pump pulley A/C compressor pulley Idler pulley
ME(H4SO)-40
Crank Pulley
MECHANICAL
13.Crank Pulley
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Use the ST to lock the crank pulley, and remove the crank pulley bolts. ST 499977100 CRANK PULLEY WRENCH (MT MODEL) ST 499977400 CRANK PULLEY WRENCH (AT MODEL)
B: INSTALLATION
1. AT MODEL
1) Install the crank pulley. 2) Use the ST to lock the crank pulley, and attach the crank pulley bolts. ST 499977400 CRANK PULLEY WRENCH (1) Clean the crankshaft thread using compressed air. (2) Apply engine oil to the crank pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (4) Tighten the crank pulley bolts. Tightening torque: 130 Nm (13.3 kgf-m, 95.9 ft-lb)
ST
ST
ME-00227
3) Remove the crank pulley.

ME-00227
3) Check that the tightening angle of the crank pulley bolt is 45 or more. Perform the following procedure when less than 45. CAUTION: If the tightening angle of crank pulley bolt is less than 45, the bolt is damaged. In this case, the bolt must be replaced. (1) Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 (2) Clean the crankshaft thread using compressed air. (3) Apply engine oil to the crank pulley bolt seat and thread. (4) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (5) Tighten the crank pulley bolts by 45 to 60. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover. 4) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
ME(H4SO)-41
Crank Pulley
MECHANICAL
2. MT MODEL
1) Install the crank pulley. 2) Use the ST to lock the crank pulley, and attach the crank pulley bolts. ST 499977100 CRANK PULLEY WRENCH (1) Clean the crankshaft thread using compressed air. (2) Apply engine oil to the crank pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (4) Tighten the crank pulley bolts. Tightening torque: 180 Nm (18.4 kgf-m, 132.8 ft-lb)
C: INSPECTION
1) Make sure the belt is not worn or otherwise damaged. 2) Check the tension of the belt. <Ref. to ME(H4SO)-40, INSPECTION, V-belt.>
ST
ME-00227
3) Check that the tightening angle of the crank pulley bolt is 65 or more. Perform the following procedure when less than 65. CAUTION: If the tightening angle of crank pulley bolt is less than 65, the bolt is damaged. In this case, the bolt must be replaced. (1) Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 (2) Clean the crankshaft thread using compressed air. (3) Apply engine oil to the crank pulley bolt seat and thread. (4) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (5) Tighten the crank pulley bolts by 65 to 75. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover. 4) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
ME(H4SO)-42
Timing Belt Cover

MECHANICAL
14.Timing Belt Cover

A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover LH. 4) Remove the front timing belt cover.
(B)
(A)
ME-00821
(A) Timing belt cover LH (B) Front timing belt cover
B: INSTALLATION
1) Install the front timing belt cover. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 2) Install the timing belt cover LH. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
(B)
(A)
ME-00821
(A) Timing belt cover LH (B) Front timing belt cover
3) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 4) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
C: INSPECTION
Check the timing belt cover for damage.
ME(H4SO)-43
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL
NOTE: Perform the work with the engine installed to body when replacing a single part. For operation procedures, refer to Timing Belt in the PM section. <Ref. to PM-20, Timing Belt.>
(d)
(c)
1. TIMING BELT
1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt guide. (MT model)
(b)
(a)
(f)
(e) ME-03952
(2) Using white paint, put an alignment mark or an arrow mark on timing belts in relation to the crank sprocket and cam sprockets.
ME-00065
5) If the alignment mark or arrow mark (which indicates the direction of rotation) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below. (1) Use the ST to turn crankshaft. Align the mark (a) of sprocket to the mark (b) of oil pump, and then ensure the right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) or left side cam sprocket mark (e), timing belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET
ME-02967
Z1: 46.8 teeth Z2: 43.7 teeth
Z1
Z2
ST ME-00231
ME-03948
6) Remove the belt idler (A).
ME(H4SO)-44
Timing Belt
MECHANICAL
7) Remove the belt idler No. 2 (B).
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
1) Prepare for installation of the automatic belt tension adjuster assembly. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-in the push adjuster rod gradually taking three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Push in the adjuster rod to the end face of the cylinder. However, do not push in the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. Do not release the press pressure until stopper pin is completely inserted. (1) Attach the automatic belt tension adjuster assembly to vertical pressing tool. (2) Slowly push in the adjuster rod with a pressure of 165 N (16.8 kgf, 37.1 lb) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder.
(A) (B)
ME-03953
8) Remove the timing belt.
ME-03949
2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY

ME-03449
ME-00239
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod.
ME-00238
ME-00350
ME(H4SO)-45
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster assembly. Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb)
3) Turn the cam sprockets No. 1 and No. 2 using ST so that their alignment marks (A) come to top positions. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used.
(A)
ME-00241
3) Install the belt idlers. Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb)
ME-03950
4) While aligning the alignment mark (B) on timing belt with the mark (A) on sprockets, position the timing belt properly.
(A) (B)
ME-03449
2. TIMING BELT
1) Prepare for installation of the automatic belt tension adjuster assembly. <Ref. to ME(H4SO)-45, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.> 2) Align the mark (A) on crank sprocket with the mark (B) on oil pump.
(A)
ME-03951
5) Install the belt idler No. 2 (B). Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb) 6) Install the belt idler (A). Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb)
(A)
(B)
ME-03975
(A) (B)
ME-03953
ME(H4SO)-46
Timing Belt
MECHANICAL
7) After ensuring the marks on timing belt and camshaft sprockets are aligned, remove the stopper pin from belt tension adjuster.
(3) Tighten the bolts mounting the timing belt guide. Tightening torque: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-00245
8) Install the timing belt guide. (MT model) (1) Temporarily tighten the bolts mounting the timing belt guide.
ME-00247
9) Install the timing belt cover. <Ref. to ME(H4SO)43, INSTALLATION, Timing Belt Cover.> 10) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 11) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
ME-00230
(2) Check and adjust the clearance between timing belt and timing belt guide by using thickness gauge. Clearance: 1.0r0.5 mm (0.039r0.020 in)
1) Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the timing belt. 2) Check the condition on the back surface of the timing belt. If cracks are found, replace the timing belt. CAUTION: Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. Do not bend the timing belt sharply. In radial diameter h: 60 mm (2.36 in) or more
h ME-00246
ME-00248
ME(H4SO)-47
Timing Belt
MECHANICAL
2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rods oil seal does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 165 N (16.8 kgf, 37.1 lb) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff and moves freely when applying 165 N (16.8 kgf, 37.1 lb), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of cylinder. Repeat this operation two to three times. (2) With the adjuster rod moved all the way up, apply a pressure of 165 N (16.8 kgf, 37.1 lb) to it, and check the adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new part. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press the adjuster rod gradually taking three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Push in the adjuster rod to the end face of the cylinder. However, do not push in the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. 4) Measure the amount of rod protrusion H from the end surface of the body. If it is not within specifications, replace the automatic belt tension adjuster assembly with a new part. Amount of rod protrusion H: 5.2 6.2 mm (0.204 0.244 in)
3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly with a new part if faulty. 2) Check the belt tension pulley for smooth rotation. Replace the automatic belt tension adjuster assembly with a new part if abnormal noise or excessive play occurs. 3) Check the belt tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace if noise or excessive play occurs. 2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check the belt idler for grease leakage.
ME-00249
ME(H4SO)-48
Cam Sprocket
MECHANICAL
16.Cam Sprocket
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt. <Ref. to ME(H4SO)-44, REMOVAL, Timing Belt.> 5) Remove the camshaft position sensor. <Ref. to FU(H4SO)-24, REMOVAL, Camshaft Position Sensor.> 6) Fasten the cam sprocket and remove from the cam shaft using ST. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used.
B: INSTALLATION
1) Fasten the cam sprocket and install to the cam shaft using ST. NOTE: Do not confuse left and right side cam sprockets during installation. They should be distinguished by the L or R indication. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. Tightening torque: 78 Nm (8.0 kgf-m, 57.5 ft-lb)
ST ME-00250
ST ME-00250
2) Install the camshaft position sensor. <Ref. to FU(H4SO)-24, INSTALLATION, Camshaft Position Sensor.> 3) Install the timing belt. <Ref. to ME(H4SO)-45, INSTALLATION, Timing Belt.> 4) Install the timing belt cover. <Ref. to ME(H4SO)43, INSTALLATION, Timing Belt Cover.> 5) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 6) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the cam sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between cam sprocket and key. 3) Check the cam sprocket protrusion used for sensor for damage and contamination of foreign matter.
ME(H4SO)-49
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt. <Ref. to ME(H4SO)-44, REMOVAL, Timing Belt.> 5) Remove the crank sprocket.
ME-00103
B: INSTALLATION
1) Install the crank sprocket.
ME-00103
2) Install the timing belt. <Ref. to ME(H4SO)-45, INSTALLATION, Timing Belt.> 3) Install the timing belt cover. <Ref. to ME(H4SO)43, INSTALLATION, Timing Belt Cover.> 4) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 5) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the crank sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between crank sprocket and key. 3) Check the crank sprocket protrusion used for sensor for damage and contamination of foreign matter.
ME(H4SO)-50
Valve Rocker Assembly

MECHANICAL
18.Valve Rocker Assembly

A: REMOVAL
NOTE: Perform the work with the engine installed to body when replacing a single part. Refer to Valve Clearance for preparation procedures. <Ref. to ME(H4SO)-27, Valve Clearance.> 1) Remove the high tension cord. 2) Disconnect the PCV hose and remove the rocker cover. 3) Remove the valve rocker assembly. (1) Use the ST to rotate the spring stopper in the direction of the arrow to remove it from adjuster pin. ST 18258AA000 SPRING INSTALLER
(2) Remove the bolts (a) through (j) in alphabetical sequence. NOTE: Leave two or three threads of bolts (i) and (j) engaged in order to retain the valve rocker assembly.
(d) (a) (j) (h) (b) (f)
(c) (e) (g) (i)
ME-02975
(3) Remove the valve rocker assembly. NOTE: Set the ST in the position shown in the drawing to remove the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER
ST
ME-02704
ST (A) (B) (C)

ME-02744
ME-02794
(A) Adjuster pin (B) Spring stopper (C) Spring
ME(H4SO)-51

MECHANICAL
B: INSTALLATION
1) Install the valve rocker assembly. (1) Temporarily tighten the bolts equally in alphabetical order as shown in the figure. NOTE: Do not temporarily tighten the bolts (i) and (j). Set the ST in the position shown in the drawing to mount the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER
(4) Use the ST to rotate the spring stopper in the direction of the arrow to fasten the adjuster pin. ST 18258AA000 SPRING INSTALLER
ST
ME-02704
ST
ME-02794
(A) (B) (C)

ME-02705
(2) Tighten the bolts (a) through (h) to specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) (3) Tighten the bolts (i) through (j) to specified torque. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
(g) (i) (a) (c) (j) (e)
(A) Adjuster pin (B) Spring stopper (C) Spring
2) Remove the timing belt cover LH. 3) Adjust the valve clearance. <Ref. to ME(H4SO)28, ADJUSTMENT, Valve Clearance.> 4) Install the timing belt cover LH. 5) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages. Tightening torque: 1st 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(h) (f) (d) (b)

ME-02703
ME(H4SO)-52

MECHANICAL
RH side
(f) (a) (c)
E: INSPECTION
1. INTAKE VALVE ROCKER ASSEMBLY
1) If the roller or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker assembly. 2) Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker assembly.
2. EXHAUST VALVE ROCKER ASSEMBLY

(d) (b) (e)
ME-02715
LH side
(f) (a) (c)
1) Measure the inner diameter of valve rocker arm and outer diameter of valve rocker shaft, and confirm the difference (oil clearance) between the two values. Clearance between arm and shaft: Standard 0.020 0.054 mm (0.0008 0.0021 in)
(d)
(b)
(e)
ME-02716
(3) Connect the PCV hose. 6) Install the high tension cord.
C: DISASSEMBLY
NOTE: Intake valve rocker assembly cannot be disassembled. 1) Remove the exhaust valve rocker arm from the rocker shaft. NOTE: Keep all the removed parts in order for re-installing in their original positions. 2) Remove the nut and adjusting screw from exhaust valve rocker.
ME-02706
ME-00257
D: ASSEMBLY
NOTE: Intake valve rocker assembly cannot be disassembled. 1) Install the adjusting screw and nut to the exhaust valve rocker. 2) Insert the exhaust valve rocker arm to rocker shaft. NOTE: Valve rocker arms, and rocker shaft have identification marks. Make sure the parts with same markings are properly assembled.
2) If the oil clearance exceeds the limit, replace the valve rocker arm or shaft, whichever shows the greater amount of wear. Rocker arm inside diameter: 22.020 22.041 mm (0.8669 0.8678 in) Rocker shaft diameter: 21.987 22.000 mm (0.8656 0.8661 in) 3) If the roller or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker arm. 4) Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker arm.
ME(H4SO)-53
Camshaft
MECHANICAL
19.Camshaft
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. Refer to Valve Clearance for preparation procedures. <Ref. to ME(H4SO)-27, Valve Clearance.> 1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt. <Ref. to ME(H4SO)-44, REMOVAL, Timing Belt.> 5) Remove the cam sprocket. <Ref. to ME(H4SO)49, REMOVAL, Cam Sprocket.> 6) Remove the timing belt cover No. 2 LH. 7) Remove the timing belt cover No. 2 RH. NOTE: Do not damage or lose the seal rubber when removing the timing belt covers.
11) Remove the camshaft cap. (1) Remove the bolts (a) and (b) in alphabetical sequence.
(a)
(b)
ME-02707
(2) Equally loosen the bolts (c) through (j) all the way in alphabetical sequence.
(j) (h)
(d)
(f)
(e) (c) (g) (i)
ME-02708
(3) Remove the bolts (k) through (p) in alphabetical sequence using ST. ST 499497000 TORX PLUS
(n) (p) (l)
ME-00258
8) Remove the tensioner bracket.

(m) (k) (o)
ME-02709
(4) Remove the camshaft cap. 12) Remove the camshaft. 13) Remove the oil seal. 14) Remove the plug from rear side of camshaft.
ME-00259
9) Remove the camshaft position sensor support. (LH side only) 10) Remove the valve rocker assembly. <Ref. to ME(H4SO)-51, REMOVAL, Valve Rocker Assembly.>
CAUTION: Do not scratch the journal surface when removing the oil seal. 15) Similarly, remove the camshaft RH and related parts.
ME(H4SO)-54
Camshaft
MECHANICAL
B: INSTALLATION
1) Apply a thin coat of engine oil to camshaft journals, and install the camshaft. 2) Install the camshaft cap. (1) Apply liquid gasket to the mating surfaces of camshaft cap. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
(4) Tighten the TORX bolts (e) through (j) in alphabetical sequence using ST. ST 499497000 TORX PLUS Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(g) (e) (i)
(h) (j) (f)

ME-02712
(5) Tighten the bolts (k) through (r) in alphabetical sequence. Tightening torque: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
(k) (m)
ME-02710
NOTE: Apply a coat of liquid gasket of 3 mm (0.12 in) in diameter (A) along the edge (B) of camshaft cap (C) mating surface.
(A)
(q)
(o)
(p) (r) (n) (l)
ME-02713
(B) (C)
(6) Tighten the bolts (s) and (t) in alphabetical sequence. NOTE: Use new seal washer. Install and tighten the seal washer to the bolt.
ME-00265
(2) Temporarily tighten the bolts (a) through (d) in alphabetical sequence.
(c)
(a)
(s)
(t) (b) (d)

ME-02714 ME-02711
(3) Install the valve rocker assembly. <Ref. to ME(H4SO)-52, INSTALLATION, Valve Rocker Assembly.>
ME(H4SO)-55
Camshaft
MECHANICAL
3) Apply a coat of engine oil to camshaft oil seal periphery and oil seal lips and install the oil seal (A) on camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499597000 OIL SEAL GUIDE ST2 499587500 OIL SEAL INSTALLER
9) Install the timing belt cover No. 2 LH. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
ST1 ME-00274 ST2 (A) ME-02596
4) Apply a coat of engine oil to plug periphery and Install the plug (A) using ST. ST 499587700 CAMSHAFT OIL SEAL INSTALLER
10) Install the cam sprocket. <Ref. to ME(H4SO)49, INSTALLATION, Cam Sprocket.> 11) Install the timing belt. <Ref. to ME(H4SO)-45, INSTALLATION, Timing Belt.> 12) Adjust the valve clearance. <Ref. to ME(H4SO)-28, ADJUSTMENT, Valve Clearance.> 13) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages. Tightening torque: 1st 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) RH side
(f) (a) (c)
(A)
ST
ME-02717
5) Install the camshaft position sensor support. (LH side only) Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 6) Similarly, install the parts on right-hand side. 7) Install the tensioner bracket. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
(d)
(b)
(e)
ME-02715
ME-00273
8) Install the timing belt cover No. 2 RH. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
ME(H4SO)-56
Camshaft
MECHANICAL
LH side
(f) (a) (c)
4) Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the standard or offset wear occurs, replace it. Cam height H:
Constant Intake Low speed Standard Standard Unit: mm (in) 40.075 40.175 (1.5778 1.5817) 35.496 35.596 (1.3975 1.4014) 40.315 40.415 (1.5872 1.5911) 39.289 39.389 (1.5468 1.5507)
(d)
(b)
(e)
ME-02716
(3) Connect the PCV hose. 14) Install the high tension cord. 15) Install the timing belt cover. <Ref. to ME(H4SO)-43, INSTALLATION, Timing Belt Cover.> 16) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 17) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
High speed Standard Exhaust Standard
Cam base circle diameter A: Intake 34.00 mm (1.3386 in) Exhaust 34.00 mm (1.3386 in) Base circle step of adjacent intake cams (low speed and high speed): 0.03 mm (0.001 in) or less
C: INSPECTION
1) Measure the bend, and repair or replace if necessary. Service limit: 0.025 mm (0.00098 in) or less
ME-00276
ME-00275
2) Check the journal for damage and wear. Replace if faulty. 3) Measure the outer diameter of camshaft journal and inner diameter of cylinder head journal, and check the difference (oil clearance) between the two values. If the oil clearance is not within the standard, replace the camshaft or cylinder head as necessary.
Oil clearance Standard Camshaft journal O.D. Journal hole I.D. Unit: mm (in) 0.055 0.090 (0.0022 0.0035) 31.928 31.945 (1.2570 1.2577) 32.000 32.018 (1.2598 1.2605)
5) Measure the thrust clearance of camshaft with setting the dial gauge at end of camshaft. If the thrust clearance is not within the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary, replace the camshaft. Standard: 0.030 0.090 mm (0.0012 0.0035 in)
ME(H4SO)-57
Cylinder Head
MECHANICAL
20.Cylinder Head
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. Refer to Valve Clearance for preparation procedures. <Ref. to ME(H4SO)-27, Valve Clearance.> When performing the work with the engine installed to body, the following parts must also be removed/installed. Front exhaust pipe <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> 1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Remove the intake manifold. <Ref. to FU(H4SO)-13, REMOVAL, Intake Manifold.> 3) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 4) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 5) Remove the timing belt. <Ref. to ME(H4SO)-44, REMOVAL, Timing Belt.> 6) Remove the cam sprocket. <Ref. to ME(H4SO)49, REMOVAL, Cam Sprocket.> 7) Remove the bolt which installs the A/C compressor bracket on cylinder head. 8) Remove the valve rocker assembly. <Ref. to ME(H4SO)-51, REMOVAL, Valve Rocker Assembly.> 9) Remove the camshaft. <Ref. to ME(H4SO)-54, REMOVAL, Camshaft.> 10) Remove the oil level gauge guide. (LH side) 11) Remove the cylinder head bolts in alphabetical sequence as shown in the figure. NOTE: Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling.
(e) (c)
12) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (a) and (c) to remove cylinder head.
(e) (c)
(a)
(b) (f) (d) ME-02745
13) Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. 14) Similarly, remove the right side cylinder head.
(a)
(b) (f) (d) ME-02745
ME(H4SO)-58
Cylinder Head
MECHANICAL
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder block and cylinder head. NOTE: Use a new cylinder head gasket. 2) Tighten the cylinder head bolts. (1) Apply a thin coat of engine oil to washer and bolt thread. (2) Tighten all bolts to 29 Nm (3.0 kgf-m, 21.4 ft-lb) in alphabetical order. (3) Tighten all bolts to 69 Nm (7.0 kgf-m, 50.9 ft-lb) in alphabetical order. (4) Loosen all the bolts by 180 in the reverse order of installing, and loosen them further by 180. (5) Tighten all bolts to 42 Nm (4.3 kgf-m, 31.0 ft-lb) in alphabetical order. (6) Tighten all bolts by 80 to 90 in alphabetical order. (7) Tighten all bolts by 40 to 45 in alphabetical order. CAUTION: The tightening angle of the bolt should not exceed 45. (8) Further tighten the bolts (a) and (b) by 40 45. CAUTION: Make sure the total re-tightening angle of the step (7) and (8) does not exceed 90.
6) Install the A/C compressor bracket on cylinder head. Tightening torque: 36 Nm (3.7 kgf-m, 26.6 ft-lb) 7) Install the cam sprocket. <Ref. to ME(H4SO)-49, INSTALLATION, Cam Sprocket.> 8) Install the timing belt. <Ref. to ME(H4SO)-45, INSTALLATION, Timing Belt.> 9) Adjust the valve clearance. <Ref. to ME(H4SO)28, ADJUSTMENT, Valve Clearance.> 10) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages. Tightening torque: 1st 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) RH side
(f) (a) (c)
(d)
(b)
(e)
(a)
(f)
ME-02715
LH side
(c)
(f) (a) (c)
(d) (b) (e) ME-02746
3) Install the oil level gauge guide. (LH side) Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 4) Install the camshaft. <Ref. to ME(H4SO)-55, INSTALLATION, Camshaft.> 5) Install the valve rocker assembly. <Ref. to ME(H4SO)-52, INSTALLATION, Valve Rocker Assembly.>
(d) (b) (e)
ME-02716
11) Install the timing belt cover. <Ref. to ME(H4SO)43, INSTALLATION, Timing Belt Cover.> 12) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 13) Install the intake manifold. <Ref. to FU(H4SO)15, INSTALLATION, Intake Manifold.> 14) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
ME(H4SO)-59
Cylinder Head
MECHANICAL
C: DISASSEMBLY
1) Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE 2) Compress the valve spring and remove the valve spring retainer key using ST. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: Keep all the removed parts in order for re-installing in their original positions. Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to Inspection. <Ref. to ME(H4SO)63, VALVE GUIDE, INSPECTION, Cylinder Head.> <Ref. to ME(H4SO)-66, INTAKE AND EXHAUST VALVE OIL SEAL, INSPECTION, Cylinder Head.>
ST
ME-00280
ME(H4SO)-60
Cylinder Head
MECHANICAL
D: ASSEMBLY
(1)
(8)
(3)
(5)
(7) (11)
(2) (9)
(4)
(6)
(12) (10) (13) (14)
ME-03110
(1) (2) (3) (4) (5)
Valve Valve guide Valve spring seat Oil seal Valve spring
(6) (7) (8) (9) (10)
Retainer Retainer key Spark plug gasket Camshaft Oil seal
(11) (12) (13) (14)
Plug Camshaft cap Valve rocker ASSY Seal washer
ME(H4SO)-61
Cylinder Head
MECHANICAL
1) Install the valve spring and valve. (1) Coat the stem of each valve with engine oil and insert the valve into the valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. (2) Set the cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE (3) Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its closecoiled end facing the seat on cylinder head. (4) Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER
E: INSPECTION
1. CYLINDER HEAD
1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE 3) Measure the warping of the cylinder head surface that mates with cylinder block using a straight edge (A) and thickness gauge (B). If the warping exceeds the limit, correct the surface by grinding it with a surface grinder. Warping limit: 0.035 mm (0.0014 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder head: 97.5 mm (3.84 in) NOTE: Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.
(A)
ST
ME-00280
(5) Compress the valve spring and fit the valve spring retainer key.
(B)
(C) (B)
(B)
(A) (C) ME-02816
ST ME-00285
(A) Retainer key (B) Valve spring (C) Retainer
(6) After installing, tap the valve spring retainers lightly with a plastic hammer for better seating.
ME(H4SO)-62
Cylinder Head
MECHANICAL
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced. Valve seat width W: Standard: Intake (A) 0.8 1.4 mm (0.03 0.055 in) Exhaust (B) 1.2 1.8 mm (0.047 0.071 in)
3. VALVE GUIDE
1) Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge. Clearance between the valve guide and valve stem: Standard: Intake 0.035 0.062 mm (0.0014 0.0024 in) Exhaust 0.040 0.067 mm (0.0016 0.0026 in)
(B)
(A)
ME-00397 (A) ME-00763
(A) Valve guide

Y X
ME-00287
ME-00289
2) If the clearance between the valve guide and valve stem exceeds the standard, replace the valve guide or valve itself, whichever shows greater amount of wear or damage. See the following procedure for valve guide replacement. Valve guide inner diameter: 6.000 6.012 mm (0.2362 0.2367 in) Valve stem outer diameters: Intake 5.950 5.965 mm (0.2343 0.2348 in) Exhaust 5.945 5.960 mm (0.2341 0.2346 in) (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1.
ME(H4SO)-63
Cylinder Head
MECHANICAL
(2) Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267800 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
(6) Check the valve guide protrusion. Valve guide protrusion L: Intake 20.0 21.0 mm (0.787 0.827 in) Exhaust 16.5 17.5 mm (0.650 0.689 in)
ST2
L ST1 ME-00290
(3) Turn the cylinder head upside down and place the ST as shown in the figure. Intake side ST 499767700 VALVE GUIDE ADJUSTER Exhaust side ST 499767800 VALVE GUIDE ADJUSTER
(A) ME-00293
(A) Valve guide
(7) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. NOTE: Apply engine oil to the ST when reaming. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. ST 499767400 VALVE GUIDE REAMER
ST
(A) ME-00291
(A) Valve guide
(4) Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head. (5) Put a new valve guide, coated with sufficient oil, in cylinder, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER Intake side ST2 499767700 VALVE GUIDE ADJUSTER Exhaust side ST2 499767800 VALVE GUIDE ADJUSTER
ST1 ST2
ME-00294
(8) After reaming, clean the valve guide to remove chips. (9) Recheck the contact condition between valve and valve seat after replacing the valve guide.
ME-00292
ME(H4SO)-64
Cylinder Head
MECHANICAL
4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and replace the valve with a new part if damaged, worn, deformed, or if H exceeds the specified limit. Head edge thickness H: Intake (A) Standard: 0.8 1.2 mm (0.03 0.047 in) Exhaust (B) Standard: 1.0 1.4 mm (0.039 0.055 in)
5. VALVE SPRING
1) Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table. 2) To measure the squareness of the valve spring, stand the valve spring on a surface plate and measure its deflection at the top of the spring using a try square.
Free length mm (in) 55.2 (2.173) 235.3 270.7 (24 27.6, Set Tension/spring 52.9 60.8)/45.0 (1.772) height 578.9 639.9 (59.1 65.3, N (kgf, lbf)/mm (in) Lift 130.3 143.9)/34.7 (1.366) Squareness 2.5, 2.4 mm (0.094 in) or less
(A)
ME-00283
(B)
ME-00758
2) Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Replace with a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake 120.6 mm (4.75 in) Exhaust 121.7 mm (4.79 in)
ME(H4SO)-65
Cylinder Head
MECHANICAL
6. INTAKE AND EXHAUST VALVE OIL SEAL

1) For the following, replace the oil seal with a new part. See the procedure 2) and subsequent for replacement procedures. When the lip is damaged. When the spring is out of the specified position. When readjusting the surfaces of valve and valve seat. When replacing the valve guide. 2) Place the cylinder head on the ST1, and press-fit the oil seal using the ST2. ST1 498267800 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE NOTE: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer, etc. or strike in. The intake valve oil seals and exhaust valve oil seals are distinguished by their colors. Color of rubber part: Intake [Gray] Exhaust [Green]
ST2
ST1
ME-00284
ME(H4SO)-66
Cylinder Block
MECHANICAL
21.Cylinder Block
A: REMOVAL
NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 2) Remove the intake manifold. <Ref. to FU(H4SO)-13, REMOVAL, Intake Manifold.> 3) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 4) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 5) Remove the timing belt. <Ref. to ME(H4SO)-44, REMOVAL, Timing Belt.> 6) Remove the crank sprocket. <Ref. to ME(H4SO)-50, REMOVAL, Crank Sprocket.> 7) Remove the generator and A/C compressor with their brackets. 8) Remove the cylinder head. <Ref. to ME(H4SO)58, REMOVAL, Cylinder Head.> 9) Remove the clutch disc and cover. (MT model) <Ref. to CL-13, REMOVAL, Clutch Disc and Cover.> 10) Remove the flywheel. (MT model) <Ref. to CL16, REMOVAL, Flywheel.> 11) Use the ST to lock the crankshaft, and remove the drive plate. (AT model) ST 498497100 CRANKSHAFT STOPPER
15) Remove the bolts which install oil pump onto cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
LU-00015
16) Remove the oil pump from cylinder block using a flat tip screwdriver. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
ME-00138
ME-00298
12) Remove the oil separator cover. 13) Remove the water by-pass pipe for heater. 14) Remove the water pump. <Ref. to CO(H4SO)15, REMOVAL, Water Pump.>
17) Remove the front oil seal from the oil pump. 18) Remove the oil pan. (1) Set the part so that the cylinder block LH is on the upper side. (2) Remove the bolts which secure oil pan to cylinder block. (3) Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter. 19) Remove the oil strainer. 20) Remove the baffle plate. 21) Remove the oil filter. <Ref. to LU(H4SO)-23, REMOVAL, Engine Oil Filter.>
ME(H4SO)-67
Cylinder Block
MECHANICAL
22) Remove the water pipe assembly.
ME-00300
(2) (3) (4)
(1)
(6) (4)
(3)
(5)
(4) (2) (1) (3)
(8) (4) (3) (1) (2) ME-02889 (7)
(1) (2) (3)
Service hole plug Gasket Snap ring
(4) (5) (6)
Piston pin Service hole cover O-ring
(7) (8)
Seal washer Washer
ME(H4SO)-68
Cylinder Block
MECHANICAL
23) Remove the service hole plugs using a hexagon wrench [14 mm].
ME-00140
24) Remove the service hole cover. 25) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
ME-00141
26) Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
ST
ME-03325
27) Similarly draw out the piston pins from #3 and #4 pistons. 28) Remove the cylinder block connecting bolt on the RH side. 29) Loosen the cylinder block connecting bolt on the LH side by 2-3 turns. 30) Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
ME(H4SO)-69
Cylinder Block
MECHANICAL
31) Separate the cylinder block LH and RH. NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
(5) (7) (1) (4)
(2) (6) (4)
(3)
(1)
(5) ME-02890
(1) (2) (3)
Cylinder block Rear oil seal Crankshaft
(4) (5)
Crankshaft bearing Piston
(6) (7)
Seal washer Washer
32) Remove the rear oil seal. 33) Remove the crankshaft along with the connecting rods. 34) Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Press the crankshaft bearing at the end opposite to locking lip to remove. Be careful not to confuse the crankshaft bearing combination. 35) Remove each piston from the cylinder block using a wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.
ME(H4SO)-70
Cylinder Block
MECHANICAL
B: INSTALLATION
(6)
(5)
(4)
(7)
(1)
(3)
(7) (6) (7) (6)
(3)
(2)
ME-03186
(1) (2) (3)
Crankshaft bearing Crankshaft Cylinder block
(4) (5)
Rear oil seal O-ring
(6) (7)
Seal washer Washer
1) Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal. 2) Position the crankshaft and O-ring on the cylinder block RH. NOTE: Use new O-rings. 3) Apply liquid gasket to the mating surfaces of cylinder block RH, and position the cylinder block LH. NOTE: Install within 5 minutes after applying liquid gasket. Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
ME-00145
ME(H4SO)-71
Cylinder Block
MECHANICAL
4) Apply a coat of engine oil to the washer and bolt thread. NOTE: Use a new seal washer. 5) Tighten the 10 mm cylinder block connecting bolts on the LH side (A D) in alphabetical order. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb)
8) Tighten the RH side cylinder block connecting bolts (E J) further in alphabetical order. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(G)
(E)
(J)
(A) (D) (I) (H) (F) ME-00841
(B) (C) ME-00840
9) Tighten the LH side cylinder block connecting bolts (A D) further in alphabetical order. (A), (C): Angle tightening Tightening angle: 90 (B), (D): Torque tightening Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
6) Tighten the 10 mm cylinder block connecting bolts on the RH side (E J) in alphabetical order. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb)
(G)
(E)
(J) (D)
(A)
(B) (I) (H) (F) ME-00841 (C) ME-00840
7) Tighten the LH side cylinder block connecting bolts (A D) further in alphabetical order. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
10) Tighten the RH side cylinder block connecting bolts (E J) further in alphabetical order. Tightening angle: 90
(A) (D)
(G)
(E)
(J)
(B) (C) ME-00840 (I) (H) (F) ME-00841
ME(H4SO)-72
Cylinder Block
MECHANICAL
11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A H) in alphabetical sequence. Tightening torque: (A) (G): 25 Nm (2.5 kgf-m, 18.4 ft-lb) (H): 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
15) Position the upper rail gap at (C) in the figure.
(C) 25 25
(G) (E) (C) (A) (B) RH
(C) LH ME-02722
16) Align the upper rail spin stopper (E) to the side hole (D) on the piston.
(D) (D) (H) (F) ME-00147 (E)
12) Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2. NOTE: Use new rear oil seal. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
(B) ST2 (F) (C) (A) 180
ME-02471
17) Position the expander gap at (F) on the 180 opposite direction of (C) in the figure.
(C) 180 ST1 ME-00148 RH LH
(F)
ME-02723
(A) Rear oil seal (B) Flywheel attaching bolt
18) Set the lower rail gap at position (G), located 120 clockwise from (C).
120 (G) (C)
13) Position the top ring gap at (A) or (B) in the figure. 14) Position the second ring gap at 180 on the reverse side the top ring gap.
180 180
(C) (G) 120 RH

(B) (A) (A) (B)
LH
ME-02724
RH
LH
ME-02721
NOTE: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area.
ME(H4SO)-73
Cylinder Block
MECHANICAL
19) Install the snap ring. Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side. NOTE: Use new snap rings.
#3
#1
#4
(A)
#2
ME-00306
(A) Front side

(5) (4) (1) (3) (2) T (5) (4) (3) (2)
(1)
ME-02442
(1) (2) (3)
Piston Piston pin Snap ring
(4) (5)
Gasket Service hole plug
Tightening torque:Nm (kgf-m, ft-lb) T: 70 (7.1, 51.6)
ME(H4SO)-74
Cylinder Block
MECHANICAL
20) Install the piston. (1) Set the parts so that the #1 and #2 cylinders are on the upper side. (2) Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE
ST1
21) Install the piston pin. (1) Apply a coat of engine oil to ST3. (2) Insert ST3 into the service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE
ST1
ST3
ME-00158
ST2 ME-00157
(3) Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. (4) Install the snap ring. NOTE: Use new snap rings.
NOTE: Face the piston front mark towards the front of the engine.
ME-00159 RH (A) LH
ME-02725
(5) Apply liquid gasket to the threaded portion of the service hole plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent
(A) Front mark
ME-00160
ME(H4SO)-75
Cylinder Block
MECHANICAL
(6) Install the service hole plug and gasket. NOTE: Use a new gasket. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
ME-00140 (5)
T2 (4)
T1 (6)
(3) (2) (1)
(7) (3) (2)
(1) ME-02440
(1) (2) (3) (4)
Piston Piston pin Snap ring Gasket
(5) (6) (7)
Service hole plug Service hole cover O-ring
ME(H4SO)-76
Cylinder Block
MECHANICAL
(7) Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins. (8) Install the service hole cover. NOTE: Use new O-rings. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 22) Install the water pipe assembly. NOTE: Use new O-rings. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
26) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
(A) LU-02353
(A) Gasket
ME-00300
23) Install the baffle plate. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 24) Install the oil strainer. NOTE: Use new O-rings. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb) 25) Tighten the oil strainer stay together with the baffle plate. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
27) Apply liquid gasket to the mating surfaces of the oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover. NOTE: Install within 5 minutes after applying liquid gasket. Use a new separator cover. Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent (A) bolt thread (when reusing bolts) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(A)
ME-03333
28) Install the flywheel. (MT model) <Ref. to CL-16, INSTALLATION, Flywheel.>
ME(H4SO)-77
Cylinder Block
MECHANICAL
29) Install the clutch disc and cover. (MT model) <Ref. to CL-13, INSTALLATION, Clutch Disc and Cover.> 30) Use the ST to lock the crankshaft, and install the drive plate. (AT model) ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 Nm (7.3 kgf-m, 53.1 ft-lb)
(3) Apply a coat of engine oil to the inside of oil seal.
ME-00312
(4) Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation. NOTE: Make sure the oil seal lip is not folded. Align the flat surface of oil pumps inner rotor with crankshaft before installation. Use new O-rings and oil seals. Do not forget to assemble O-rings. (5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: T: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
ST
ME-00298
31) Install the oil pump. (1) Install the front oil seal using the ST. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal.
LU-00021
(2) Apply liquid gasket to the matching surface of oil pump. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
T LU-02103
(A)
ME-00165
(A) O-ring
ME(H4SO)-78
Cylinder Block
MECHANICAL
32) Install the water pump and gasket. NOTE: When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure. Use a new gasket. Tightening torque: First: 12 Nm (1.2 kgf-m, 8.9 ft-lb) Second: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
(B) (C) (A) (D)
40) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages. Tightening torque: 1st 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) RH side
(f) (a) (c)
(E)
(F)
ME-02463
33) Install the water by-pass pipe for heater. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 34) Install the oil filter. <Ref. to LU(H4SO)-23, INSTALLATION, Engine Oil Filter.> 35) Install the cylinder head. <Ref. to ME(H4SO)59, INSTALLATION, Cylinder Head.> 36) Install the generator and A/C compressor with their brackets. Tightening torque: 36 Nm (3.7 kgf-m, 26.6 ft-lb) 37) Install the crank sprocket. <Ref. to ME(H4SO)50, INSTALLATION, Crank Sprocket.> 38) Install the timing belt. <Ref. to ME(H4SO)-45, INSTALLATION, Timing Belt.> 39) Adjust the valve clearance. <Ref. to ME(H4SO)-28, ADJUSTMENT, Valve Clearance.>
(d)
(b)
(e)
ME-02715
LH side
(f) (a) (c)
(d)
(b)
(e)
ME-02716
41) Install the timing belt cover. <Ref. to ME(H4SO)-43, INSTALLATION, Timing Belt Cover.> 42) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 43) Install the intake manifold. <Ref. to FU(H4SO)15, INSTALLATION, Intake Manifold.> 44) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>
ME(H4SO)-79
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(1) (2)
(2)
(7)
(5)
(4)
(3) (6)
ME-03562
(1) (2) (3)
Connecting rod cap Connecting rod bearing Top ring
(4) (5)
Second ring Oil ring
(6) (7)
Snap ring Connecting rod
1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Keep the removed connecting rods, connecting rod caps and bearings in order so that they are kept in their original combinations/groups, and not mixed together. 3) Remove the piston rings using piston ring expander. 4) Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order, to prevent confusion. 5) Remove the snap ring.
ME(H4SO)-80
Cylinder Block
MECHANICAL
D: ASSEMBLY
(3) T (1)
(1) (2)
(4)
(5)
(8)
(6)
(7) ME-03154
(1) (2) (3) (4)
Connecting rod bearing Connecting rod Connecting rod cap Oil ring
(5) (6) (7) (8)
Second ring Top ring Snap ring Side mark
1) Apply engine oil to the surface of the connecting rod bearings, and install the connecting rod bearings on connecting rods and connecting rod caps. 2) Position each connecting rod with the side with a side mark facing forward, and install it. 3) Attach the connecting rod cap, and tighten with connecting rod nut. Make sure the arrow on connecting rod cap faces the front during installation. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads. Tightening torque: 45 Nm (4.6 kgf-m, 33.2 ft-lb) 4) Install the oil ring upper rail, expander and lower rail by hand. 5) Install the second ring and top ring using piston ring expander. NOTE: Assemble so that the piston ring mark R faces the top side of the piston.
ME(H4SO)-81
Cylinder Block
MECHANICAL
E: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Check the oil passages for clogging. 3) Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.025 mm (0.00098 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)
2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the front upper face of the cylinder block. NOTE: Measurement should be performed at a temperature of 20C (68F). Standard sized pistons are classified into two grades, A and B. These grades should be used as guide lines in selecting a standard piston. Standard diameter: A: 99.505 99.515 mm (3.9175 3.9179 in) B: 99.495 99.505 mm (3.9171 3.9175 in)
(A)
(B)
#5 #4 #3 #2 #1
(E) (C) ME-00170
(A) (B) (C) (D) (E) (F)
Main journal size mark Cylinder block (RH) (LH) combination mark #1 cylinder bore size mark #2 cylinder bore size mark #3 cylinder bore size mark #4 cylinder bore size mark
ME(H4SO)-82
4 5 B A
(F) (D)
Cylinder Block
MECHANICAL
2) Measure inner diameter of each cylinder. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20C (68F). Taper: Standard: 0.015 mm (0.0006 in) Out-of-roundness: Standard: 0.010 mm (0.0004 in)
(A) (B)
4) Measure outer diameter of each piston. Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20C (68F). Piston grade point H: 38.2 mm (1.504 in) Piston outer diameter: Standard A: 99.505 99.515 mm (3.9175 3.9179 in) B: 99.495 99.505 mm (3.9171 3.9175 in) 0.25 mm (0.0098 in) oversize: 99.745 99.765 mm (3.9270 3.9277 in) 0.50 mm (0.0197 in) oversize: 99.995 100.015 mm (3.9368 3.9376 in)
H H1 H2 H3 H4 ME-00172
5) Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20C (68F).
ME-00171
(A) (B) H1 H2 H3 H4
Piston pin direction Thrust direction 10 mm (0.39 in) 45 mm (1.77 in) 80 mm (3.15 in) 115 mm (4.53 in)
Cylinder to piston clearance at 20C (68F): Standard: 0.010 0.010 mm (0.00039 0.00039 in)
3) When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance.
ME(H4SO)-83
Cylinder Block
MECHANICAL
6) Boring and honing (1) If any of the measured value of taper, out-ofroundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston. CAUTION: When any of the cylinders needs reboring, other cylinders must be bored at the same time, and replaced with oversize pistons. (2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature. Cylinder inner diameter boring limit (diameter): To 100.005 mm (3.9372 in)
4) Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.
(A)
ME-00175
5) Check the piston pin snap ring for distortion, cracks and wear.
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: The top ring and second ring have the mark to determine the direction for installing. When installing the ring to piston, face these marks to the top side. Oil ring consists of the upper rail, expander and lower rail. When installing the oil ring on piston, be careful of each rails direction.
3. PISTON AND PISTON PIN

1) Check the piston and piston pin for breaks, cracks or wear. Replace if faulty. 2) Check the piston ring groove for wear and damage. Replace if faulty. 3) Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20C (68F). Replace if faulty. Clearance between piston hole and piston pin: Standard 0.004 0.008 mm (0.0002 0.0003 in)
(A) (B) (C)
(A)
ME-00173
(B)
(C)
ME-02480
ME-00174
(A) Upper rail (B) Expander (C) Lower rail
ME(H4SO)-84
Cylinder Block
MECHANICAL
2) Using the piston, insert the piston ring and oil ring into the cylinder so that they are perpendicular to the cylinder wall, and measure the piston ring gap with a thickness gauge.
Standard mm (in) 0.20 0.35 (0.0079 0.0138) 0.37 0.52 (0.0146 0.0205) 0.20 0.50 (0.0079 0.0197)
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)
(A)
Top ring Piston ring gap Second ring Oil ring rail
(B)
ME-00177
3) Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring.
Standard mm (in) 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028)
(A)
(B)
ME-00179
Clearance between piston ring and piston ring groove
Top ring Second ring
(A) Thickness gauge (B) Connecting rod
3) Install the connecting rod with bearings attached to the crankshaft, and measure the thrust clearance using a thickness gauge. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod. Connecting rod thrust clearance: Standard 0.070 0.330 mm (0.0028 0.0130 in)
ME-00178
ME-00180
4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
ME(H4SO)-85
Cylinder Block
MECHANICAL
5) Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. Connecting rod oil clearance: Standard 0.016 0.044 mm (0.0006 0.0017 in)
Bearing Standard 0.03 (0.0012) Undersize 0.05 (0.0020) Undersize 0.25 (0.0098) Undersize Bearing size (Thickness at center) 1.492 1.501 (0.0587 0.0591) 1.510 1.513 (0.0594 0.0596) 1.520 1.523 (0.0598 0.0600) 1.620 1.623 (0.0638 0.0639) Unit: mm (in) Outer diameter of crank pin 51.984 52.000 (2.0466 2.0472) 51.954 51.970 (2.0454 2.0461) 51.934 51.950 (2.0446 2.0453) 51.734 51.750 (2.0368 2.0374)
8) The replacement procedure for the connecting rod small end bushing is as follows. (1) Remove the bushing from connecting rod with ST and press. (2) Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER
ST
ME-00182
6) Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged. 7) Measure the piston pin clearance at connecting rod small end. If the measured value is not within the standard, replace it with a new part. Clearance between piston pin and bushing: Standard 0 0.022 mm (0 0.0009 in)
(3) Make two 3 mm (0.12 in) holes in the pressed bushing to match the pre-manufactured holes on the connecting rod, then ream the inside of the bushing. (4) After completion of reaming, clean the bushing to remove chips.
6. CRANKSHAFT AND CRANKSHAFT BEARING

1) Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft. 2) Measure the bend of crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
ME-00181
ME-00183 ME-00174
ME(H4SO)-86
Cylinder Block
MECHANICAL
3) Inspect the crank journal and crank pin for wear. If they are not within the specification, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in) Grinding limit (dia.) To 51.750 mm (2.0374 in) Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 59.758 mm (2.3527 in)
ME-00184
Unit: mm (in) Crank journal outer diameter #1, #3 #2, #4, #5 59.992 60.008 59.992 60.008 (2.3619 2.3625) (2.3619 2.3625) 1.998 2.011 2.000 2.013 (0.0787 0.0792) (0.0787 0.0793) 59.962 59.978 (2.3607 2.3613) 2.017 2.020 (0.0794 0.0795) 59.942 59.958 (2.3599 2.3605) 2.027 2.030 (0.0798 0.0799) 59.742 59.758 (2.3520 2.3527) 2.127 2.130 (0.0837 0.0839) 59.962 59.978 (2.3607 2.3613) 2.019 2.022 (0.0795 0.0796) 59.942 59.958 (2.3599 2.3605) 2.029 2.032 (0.0799 0.0800) 59.742 59.758 (2.3520 2.3527) 2.129 2.132 (0.0838 0.0839) Crank pin outer diameter 51.984 52.000 (2.0466 2.0472) 1.492 1.501 (0.0587 0.0591) 51.954 51.970 (2.0454 2.0461) 1.510 1.513 (0.0594 0.0596) 51.934 51.950 (2.0446 2.0453) 1.520 1.523 (0.0598 0.0600) 51.734 51.750 (2.0368 2.0374) 1.620 1.623 (0.0638 0.0639)
Journal O.D. Standard Bearing size (Thickness at center) Journal O.D. Bearing size (Thickness at center) Journal O.D. Bearing size (Thickness at center) Journal O.D. Bearing size (Thickness at center)
0.03 (0.0012) Undersize
0.05 (0.0020) Undersize
0.25 (0.0098) Undersize
ME(H4SO)-87
Cylinder Block
MECHANICAL
4) Use a thickness gauge to measure the thrust clearance of crankshaft at #5 crank journal bearing. If the thrust clearance is not within the standard, replace the bearing. Crankshaft thrust clearance: Standard 0.030 0.115 mm (0.0012 0.0045 in)
ME-00322
5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear. 6) Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 0.030 mm (0.0004 0.0012 in)
ME(H4SO)-88
Oil Switching Solenoid Valve

MECHANICAL
22.Oil Switching Solenoid Valve

A: REMOVAL
1. RH SIDE
9) Remove the oil switching solenoid valve holder from the cylinder head.
(A) (B) (C)
(D) (E)
ME-02726
IN-00203
2) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 3) Remove the bolt, and disconnect the engine harness connector from the bulk head harness connector and rear engine hanger.
(A) (B) (C) (D) (E)
Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil temperature sensor Oil switching solenoid valve holder Gasket
2. LH SIDE
FU-03924
IN-00203
4) Slide the bulkhead harness connector in the direction of the arrow and remove the rear engine hanger.
FU-03925
5) Disconnect the connector from the oil switching solenoid valve. 6) Remove the oil switching solenoid valve. 7) Remove the variable valve lift diagnosis oil pressure switch. <Ref. to FU(H4SO)-33, REMOVAL, Variable Valve Lift Diagnosis Oil Pressure Switch.> 8) Remove the oil temperature sensor. <Ref. to FU(H4SO)-34, REMOVAL, Oil Temperature Sensor.>
2) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 3) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 4) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 5) Remove the timing belt. <Ref. to ME(H4SO)-44, REMOVAL, Timing Belt.> 6) Remove the cam sprocket. <Ref. to ME(H4SO)49, REMOVAL, Cam Sprocket.> 7) Remove the timing belt cover No. 2 (LH). 8) Disconnect the connector from the oil switching solenoid valve. 9) Remove the oil switching solenoid valve. 10) Remove the variable valve lift diagnosis oil pressure switch. <Ref. to FU(H4SO)-33, REMOVAL, Variable Valve Lift Diagnosis Oil Pressure Switch.>
ME(H4SO)-89

MECHANICAL
11) Remove the oil switching solenoid valve holder from the cylinder head.
(B)
B: INSTALLATION
1. RH SIDE
Install in the reverse order of removal. NOTE: Use a new gasket. Apply liquid gasket to variable valve lift diagnosis oil pressure switch threads. Install the oil switching solenoid valve to the holder, then install it to the cylinder head.
(D) (C) (A)

ME-02727
(A) (B) (C) (D)
Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil switching solenoid valve holder Gasket
Tightening torque: T1: 8 Nm (0.8 kgf-m, 5.9 ft-lb) T2: 10 Nm (1.0 kgf-m, 7.4 ft-lb) T3: 17 Nm (1.7 kgf-m, 12.5 ft-lb) T4: 18 Nm (1.8 kgf-m, 13.3 ft-lb) Liquid gasket THREE BOND 1324 (Part No. 004403042) or equivalent
T1 (B) T3 (A) T4 T2 (C)
(D) (E) ME-03002
(A) (B) (C) (D) (E)
Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil temperature sensor Oil switching solenoid valve holder Gasket
FU-03924
ME(H4SO)-90

MECHANICAL
2. LH SIDE
Install in the reverse order of removal. NOTE: Use a new gasket. Apply liquid gasket to variable valve lift diagnosis oil pressure switch threads. Install the oil switching solenoid valve to the holder, then install it to the cylinder head. Tightening torque: T1: 8 Nm (0.8 kgf-m, 5.9 ft-lb) T2: 10 Nm (1.0 kgf-m, 7.4 ft-lb) T3: 17 Nm (1.7 kgf-m, 12.5 ft-lb) Liquid gasket THREE BOND 1324 (Part No. 004403042) or equivalent
(B) T3
T2 (C) (A)
(D) T1 ME-03003
(A) (B) (C) (D)
Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil switching solenoid valve holder Gasket
ME(H4SO)-91
Intake and Exhaust Valve

MECHANICAL
23.Intake and Exhaust Valve

A: SPECIFICATION
Refer to Cylinder Head for removal and installation procedures of the intake and exhaust valves. <Ref. to ME(H4SO)-58, REMOVAL, Cylinder Head.> <Ref. to ME(H4SO)-59, INSTALLATION, Cylinder Head.>
ME(H4SO)-92
Piston
MECHANICAL
24.Piston
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of pistons. <Ref. to ME(H4SO)-67, REMOVAL, Cylinder Block.> <Ref. to ME(H4SO)71, INSTALLATION, Cylinder Block.>
ME(H4SO)-93
Connecting Rod
MECHANICAL
25.Connecting Rod
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of connecting rods. <Ref. to ME(H4SO)-67, REMOVAL, Cylinder Block.> <Ref. to ME(H4SO)-71, INSTALLATION, Cylinder Block.>
ME(H4SO)-94
Crankshaft
MECHANICAL
26.Crankshaft
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of the crankshaft. <Ref. to ME(H4SO)-67, REMOVAL, Cylinder Block.> <Ref. to ME(H4SO)-71, INSTALLATION, Cylinder Block.>
ME(H4SO)-95
Engine Trouble in General

MECHANICAL
27.Engine Trouble in General

A: INSPECTION
NOTE: The RANK shown in the chart shows the possibilities of the cause of trouble in order from Very often to Rarely. A Very often B Sometimes C Rarely
Symptoms 1. Engine does not start. 1) Starter does not turn. Problem parts etc. Starter Possible cause RANK B C C B A A B C C C C A A B B B B C C C C C B C B B
2) Initial combustion does not occur.
Defective battery-to-starter harness Defective starter switch Defective inhibitor switch Defective starter Battery Improper connection of the terminal Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Starter Defective starter Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)
ME(H4SO)-96

MECHANICAL
Symptoms 3) Initial combustion occurs. Problem parts etc. Possible cause Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) RANK A B B C C B B B C C C C C B C B B A B C C B B C C B B B C C C C C B C B B
4) Engine stalls after initial combustion.
ME(H4SO)-97

MECHANICAL
Symptoms 2. Rough idle and engine stall Problem parts etc. Possible cause Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Over-heating Others Evaporative emission control system malfunction Stuck or damaged throttle valve RANK A A A A B B C B C C C B C B B B B C B B A B B C C A B
ME(H4SO)-98

MECHANICAL
Symptoms 3. Low output, hesitation and poor acceleration Problem parts etc. Possible cause Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Cooling system Over-heating Over-cooling Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Cooling system Over-heating Others Evaporative emission control system malfunction RANK A A A B B B B B A B B C B B B B B C B C A B B C C A A A A A B B B B B B B C B B C C C C C C A B B C
4. Surging
ME(H4SO)-99

MECHANICAL
Symptoms 5. Engine does not return to idle. 6. Dieseling (Run-on) Problem parts etc. Possible cause RANK A A A A B B A C C B B C B B C C B C C C A C C C A B B C B A A B C A A B B B B B B
7. After burning in exhaust system
8. Knocking
9. Excessive engine oil consumption
Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Over-heating Intake system Loosened or cracked PCV hose Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter gasket Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan
ME(H4SO)-100

MECHANICAL
Symptoms Problem parts etc. Possible cause 10. Excessive fuel consump- Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> tion Intake system Dirty air cleaner element Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling RANK A A B B C C B C C B B C C
ME(H4SO)-101
Engine Noise
MECHANICAL
28.Engine Noise
A: INSPECTION
Type of sound Condition Sound increases as engine speed increases. Possible cause Valve mechanism is defective. Incorrect valve clearance Worn valve rocker Worn camshaft Broken valve spring Worn crankshaft main bearing Worn connecting rod bearing (large end) Damaged engine mounting Loosened flywheel mounting bolt Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong heat range of spark plug Improper octane value of gasoline Worn crankshaft main bearing Worn connecting rod bearing (large end)
Regular clicking sound
Oil pressure is low. Heavy and dull clank Oil pressure is normal. High-pitched clank (Spark knock) Sound is noticeable when accelerating with an overload condition.
Clank when engine speed is 1,000 to 2,000 rpm
Sound is reduced when fuel injector connector of noisy cylinder is disconnected. (NOTE*) Sound is reduced when fuel injector connector of noisy cylinder is disconnected. (NOTE*) Sound is not reduced if each fuel injector connector is disconnected in turn. (NOTE*)
Knocking sound when engine is operating under idling speed and engine is warm
Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Worn cam sprocket Worn camshaft journal bore in cylinder head Insufficient generator lubrication Poor contact of generator brush and rotor Defective ignition starter switch Worn gear and starter pinion Loose V-belt Defective water pump shaft Insufficient compression Air leakage in air intake system, hose, connection or manifold Loose timing belt Timing belt contacting with adjacent part Incorrect valve clearance
Squeaky sound Rubbing sound Gear scream when starting engine Sound like polishing glass with a dry cloth Hissing sound Timing belt noise Valve noise
NOTE*) When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H4SO)-102
General Description
EXHAUST
A: COMPONENT
(5) (8) (29) T1
(5) (7) (5) T9 (6) (2) (1) (4) (3) T9 (5) (6) (7)
(9)
(29) T1
(5)
T4 (18) T2 T4 (16) (24) (28) (10) (23) (22) T2 (12) (20) (14) (17) (19) T8 (15) T2 (20) (25) T6 T6 T6 T2 (21) T2 (26) (27) (30) T7 (31) T5 T2 (13) T2 T3 (11)
T2
EX-02365
EX(H4SO)-2
General Description
EXHAUST
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) Gasket Spring Chamber Rear exhaust pipe Cushion rubber Self-locking nut Gasket Muffler RH Muffler LH Center exhaust pipe front upper cover Rear catalytic converter upper cover Center exhaust pipe Rear catalytic converter Rear catalytic converter lower cover (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) Center exhaust pipe front lower cover (28) (29) Band Muffler cutter (model with muffler cutter)
Front oxygen (A/F) sensor Front catalytic converter (30) Hanger bracket (MT model) Rear oxygen sensor (31) Hanger bracket (AT model) Gasket Gasket Tightening torque:Nm (kgf-m, ft-lb) Front exhaust pipe T1: 7.5 (0.8, 5.5) Front exhaust pipe upper cover LH T2: 13 (1.3, 9.6) Front exhaust pipe upper cover RH T3: 18 (1.8, 13.3) Front catalytic converter upper T4: 21 (2.1, 15.5) cover T5: 23 (2.3, 17.0) Front catalytic converter lower T6: 30 (3.1, 22.1) cover T7: 35 (3.6, 25.8) Front exhaust pipe lower cover RH T8: 40 (4.1, 29.5) Front exhaust pipe lower cover LH T9: 48 (4.9, 35.4)
B: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. If any fat adheres to the exhaust pipe, wipe it off. Otherwise a fire may happen.
EX(H4SO)-3
Front Exhaust Pipe

EXHAUST
2. Front Exhaust Pipe

A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery.
8) Remove the nuts which hold front exhaust pipe onto cylinder heads. CAUTION: Be careful not to drop the front and center exhaust pipe assembly.
EX-02122
9) Remove the bolt which holds center exhaust pipe to hanger bracket.
IN-00203
3) Remove the air intake duct. <Ref. to IN(H4SO)8, REMOVAL, Air Intake Duct.> 4) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) and remove the clip (C) fastening the harness.
(B) (A) EX-02240
10) Remove the front and center exhaust pipe assembly from the vehicle.
(C)
EX-02350
5) Lift up the vehicle. 6) Remove the under cover. 7) Separate the center exhaust pipe from rear exhaust pipe.
CAUTION: Be careful not to let the front and center exhaust pipe assembly fall off when removing as it is quite heavy. After removing the front and center exhaust pipe assemblies, do not pull on the rear exhaust pipe with excessive force. 11) Separate the front exhaust pipe from center exhaust pipe.
EX-02241
EX-02124
12) Remove the front oxygen (A/F) sensor and rear oxygen sensor. <Ref. to FU(H4SO)-35, REMOVAL, Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO)-37, REMOVAL, Rear Oxygen Sensor.>
EX(H4SO)-4
Front Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear oxygen sensor to the front exhaust pipe. <Ref. to FU(H4SO)-36, INSTALLATION, Front Oxygen (A/ F) Sensor.> <Ref. to FU(H4SO)-38, INSTALLATION, Rear Oxygen Sensor.> 2) Install the front exhaust pipe to center exhaust pipe. NOTE: Use a new gasket. Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
5) Tighten the bolt which holds center exhaust pipe to rear exhaust pipe. NOTE: Use a new gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-02241
6) Tighten the bolt which holds center exhaust pipe to hanger bracket. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
EX-02124
3) Install the front and center exhaust pipe assembly to the vehicle. NOTE: Use a new gasket. 4) Temporarily tighten the nuts which hold front exhaust pipe to cylinder heads.
EX-02240
7) Tighten the nuts which hold front exhaust pipe to cylinder heads. Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft-lb)
EX-02122
EX-02122
8) Install the under cover. 9) Lower the vehicle.
EX(H4SO)-5
Front Exhaust Pipe

EXHAUST
10) Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B), and fasten the harness with the clip (C).
(B) (A)
(C)
EX-02350
11) Install the air intake duct. <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Duct.> 12) Connect the ground cable to battery.
IN-00203
C: INSPECTION
1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.
EX(H4SO)-6
Center Exhaust Pipe

EXHAUST
3. Center Exhaust Pipe

A: REMOVAL
1) After removing the center and front exhaust pipes as one unit, separate them. Refer to Front Exhaust Pipe for the removal procedure. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> 2) Remove the front oxygen (A/F) sensor and rear oxygen sensor. <Ref. to FU(H4SO)-35, REMOVAL, Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO)-37, REMOVAL, Rear Oxygen Sensor.>
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear oxygen sensor. <Ref. to FU(H4SO)-36, INSTALLATION, Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO)-38, INSTALLATION, Rear Oxygen Sensor.> 2) Install the center exhaust pipe and front exhaust pipe as one unit. Refer to Front Exhaust Pipe for the installation procedure. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
EX(H4SO)-7
Rear Exhaust Pipe

EXHAUST
4. Rear Exhaust Pipe

A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Separate the rear exhaust pipe from center exhaust pipe.
6) Remove the rear exhaust pipe bracket from cushion rubber.
EX-00219
7) Remove the rear exhaust pipe.
B: INSTALLATION
1) Apply a coat of spray type lubricant to the mating area of cushion rubber. 2) Install the rear exhaust pipe bracket to cushion rubber.
EX-02241
4) Separate the rear exhaust pipe from muffler. CAUTION: Be careful not to drop the rear exhaust pipe. LH side
NOTE: After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.
EX-00219
3) Install the rear exhaust pipe to muffler.

EX-00222
RH side
NOTE: Use a new gasket and self-locking nut. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb) LH side
EX-00218
5) Apply a coat of spray type lubricant to the mating area of cushion rubber.
EX-00222
EX(H4SO)-8
Rear Exhaust Pipe

EXHAUST
RH side
EX-00218
4) Install the rear exhaust pipe to center exhaust pipe. NOTE: Use a new gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-02241
C: INSPECTION
1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. 3) Check the cushion rubber for wear or crack.
EX(H4SO)-9
Muffler
EXHAUST
5. Muffler
A: REMOVAL
CAUTION: Be careful not to burn yourself, because the exhaust pipe becomes extremely hot after running. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Separate the muffler from rear exhaust pipe. LH side
RH side
EX-00221
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use a new gasket and self-locking nut. After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.
EX-00222
RH side
Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb) LH side
EX-00218
EX-00222
4) Apply a coat of spray type lubricant to the mating area of cushion rubber. 5) Remove the front and rear cushion rubber, and then remove the muffler. CAUTION: Be careful not to drop the muffler during removal. LH side
RH side
EX-00218
C: INSPECTION
EX-00220
EX(H4SO)-10
General Description
COOLING
A: SPECIFICATION
Cooling system Total engine coolant capacity Type Discharge performance I Discharge rate 2 (US gal, Imp gal) /min. Pump speed Discharge pressure Engine coolant temperature Discharge rate 2 (US gal, Imp gal) /min. Pump speed Discharge pressure Engine coolant temperature 2 (US qt, Imp qt) Electric fan + Forced engine coolant circulation system MT: approx. 6.4 (6.8, 5.6) AT: Approx. 6.3 (6.7, 5.5) Centrifugal impeller type 20 (5.3, 4.4) 760 rpm 2.9 kPa (0.3 mAq) 80C (176F) 100 (26.4, 22.0) 3,000 rpm 49 kPa (5.0 mAq) 80C (176F)
Discharge performance II Water pump
Thermostat
Radiator fan
Discharge rate 2 (US gal, Imp gal) /min. 200 (52.8, 44.0) Discharge performance III Pump speed Discharge pressure 6,000 rpm 225.4 kPa (23 mAq) Engine coolant temperature 80C (176F) Impeller diameter mm (in) 76 (2.99) Number of impeller vanes 8 Pump pulley diameter mm (in) 60 (2.36) Clearance between impeller and case Standard mm (in) 0.5 1.5 (0.020 0.060) Type Wax pellet type Starting temperature to open 80 84C (176 183F) Fully opens 95C (203F) Valve lift mm (in) 9.0 (0.354) or more Valve bore mm (in) 35 (1.38) Main fan 90 W Motor input Sub fan 90 W Main fan 300 mm (11.81 in)/4 Fan diameter / Blade Sub fan 300 mm (11.81 in)/5 Type Core dimensions Width Height Thickness mm (in) Down flow, pressure type 687.4 340 16 (27.06 13.39 0.63) Above: 108r15 or more (1.1r0.15, 16r2) Below: 1.0 to 4.9 or less (0.01 0.05, 0.1 0.7) Corrugated fin type 0.45 (0.48, 0.40) Alternative Soft water or tap water
Radiator Pressure range in which cap valve is open Fins Capacity Recommended materials SUBARU SUPER COOLANT (Concentrated type) SUBARU SUPER COOLANT (Diluted type) Distilled water Cooling system conditioner kPa (kg/cm2, psi)
Reservoir tank
2 (US qt, Imp qt) Item number K0670Y0000 SOA345001
Coolant Water for dilution Cooling system protective agent
CO(H4SO)-2
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(2)
(1)
T1
(7) T1 (7) (3)
(4)
T2
(5)
(6)
CO-02484
(1) (2) (3) (4)
Water pump ASSY Gasket Heater by-pass hose Thermostat
(5) (6) (7)
Gasket Thermostat cover Clip
Tightening torque:Nm (kgf-m, ft-lb) T1: First 12 (1.2, 8.9) Second 12 (1.2, 8.9) T2: 12 (1.2, 8.9)
CO(H4SO)-3
General Description
COOLING
2. RADIATOR & RADIATOR FAN

T2 (6) (5)
T1
(5) T3 (10) (4) T4 (7) T5 (3) T4 (12) (11) T2 T1
(8)
(24)
(13) (25) (2)
(9)
T2 (14) (16)
B T2
(15)
(5) (22) (21) A
(20)
(17) (14) (1) (5) B (23) A (18) (14) T2
(14)
(19) CO-02353
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Radiator lower cushion Radiator Radiator upper cushion Radiator upper bracket Clip Radiator inlet hose Engine coolant reservoir tank cap Over flow hose Engine coolant reservoir tank Radiator sub fan shroud Radiator sub fan, radiator sub fan motor ASSY
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21)
Radiator main fan shroud Radiator main fan, radiator main fan motor ASSY ATF hose clip (AT model) ATF hose A (AT model) ATF hose B (AT model) ATF pipe (AT model) ATF hose C (AT model) ATF hose D (AT model) Radiator outlet hose Radiator drain plug
(22) (23) (24) (25)
O-ring Radiator lower bracket Radiator cap Heat shield cover (AT model)
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 7.5 (0.8, 5.5) T3: 12 (1.2, 8.9) T4: 3.4 (0.3, 2.5) T5: 3 (0.3, 2.2)
CO(H4SO)-4
General Description
COOLING
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. Follow all government and local regulations concerning disposal of refuse when disposing engine coolant.
CO(H4SO)-5
General Description
COOLING
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 499977100 DESCRIPTION CRANK PULLEY WRENCH REMARKS Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (MT model)
ST-499977100
499977400
CRANK PULLEY WRENCH
ST-499977400
18231AA010
CAM SPROCKET WRENCH
Used for removing and installing cam sprocket. CAM SPROCKET WRENCH (499207100) can also be used.
ST18231AA010
1B022XU0
ST1B022XU0
2. GENERAL TOOL
TOOL NAME Radiator cap tester REMARKS Used for checking radiator and radiator cap.
CO(H4SO)-6
Radiator Fan System

COOLING
2. Radiator Fan System

A: WIRING DIAGRAM
BATTERY MAIN SBF SBF-6
No.3 IGNITION SWITCH No.4 No.26
MAIN FUSE BOX (M/B) B: B143 C: E: F35 F36 C10 B7 E6 E5
No.22 MAIN FAN RELAY 1
THROUGH JOINT CONNECTOR 10 F109 20 21 10 13 1 B360
MAIN FAN RELAY 2 MAIN FAN MOTOR 22 19 18 11 F17 12
SUB FAN RELAY
RELAY HOLDER F27
M
1
THROUGH JOINT CONNECTOR 16 F16 F108 1 2 7 B361 18 29 B136 ECM SUB FAN MOTOR F16 F17 2 1 B136 B: B143 C: F35 E: F36 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35 8 10 11 12 13 B361 4 5 6 1 2 3 7 8 9 10 11 12 13 14 B360 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 F108 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 F109 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3 4 5 6 7 9 14 15 16 17 1 2 18 19 20 21 22 F27
E M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12
1 2 4 5
3 7
CO-02319
CO(H4SO)-7
Radiator Fan System

COOLING
B: INSPECTION
DETECTING CONDITION:
Increase: 94C (201F) or less Decrease: 92C (198F) or less Radiator fan operation OFF Low-Speed High-Speed OFF High-Speed High-Speed OFF OFF Low-Speed OFF OFF OFF Engine coolant temperature Increase: 95 99C Increase: 100C (203 210F) (212F) or more Decrease: 95C Decrease: 93 94C (203F) or more (199 201F) Radiator fan operation Radiator fan operation Low-Speed High-Speed Low-Speed High-Speed High-Speed Low-Speed High-Speed High-Speed Low-Speed Low-Speed High-Speed OFF Low-Speed Low-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed
Vehicle speed
A/C compressor load
During acceleration: 19 km/h (12 MPH) or less During deceleration: 10 km/h (6 MPH) or less During acceleration: 20 69 km/h (12 43 MPH) During deceleration: 11 64 km/h (7 40 MPH) During acceleration: 70 134 km/h (43 83 MPH) During deceleration: 65 129 km/h (40 80 MPH) During acceleration: 135 km/h (84 MPH) or more During deceleration: 130 km/h (81 MPH) or more
OFF Low High OFF Low High OFF Low High OFF Low High
TROUBLE SYMPTOMS: Radiator main fan and radiator sub fans do not rotate under the above operating conditions.
1 Step Check CHECK OPERATION OF RADIATOR FAN. Do the radiator main fans and 1) Connect the delivery (test) mode connector. radiator sub fans rotate at low 2) Turn the ignition switch to ON. speed? 3) Using the Subaru Select Monitor, check the forced operation of the radiator fan relay. NOTE: When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution o high speed revolution o OFF in this order. Subaru Select Monitor Refer to Compulsory Valve Operation Check Mode for detailed procedures. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> Yes Go to step 2. No Go to step 3.
CO(H4SO)-8
Radiator Fan System

COOLING
Step CHECK OPERATION OF RADIATOR FAN. 1) Connect the delivery (test) mode connector. 2) Turn the ignition switch to ON. 3) Using the Subaru Select Monitor, check the forced operation of the radiator fan relay. NOTE: When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution o high speed revolution o OFF in this order. Subaru Select Monitor Refer to Compulsory Valve Operation Check Mode for detailed procedures. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Remove the sub fan relay from the relay holder. 3) Measure the voltage between the sub fan relay terminal and chassis ground. Connector & terminal (F27) No. 10 (+) Chassis ground (): CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between the sub fan relay terminal and chassis ground. Connector & terminal (F27) No. 13 (+) Chassis ground (): CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 3. 3) Check the condition of fuse. CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 22. 3) Check the condition of fuse. CHECK SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 No. 11: CHECK SUB FAN RELAY. 1) Connect the battery to terminals No. 13 and No. 12 of the sub fan relay. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 No. 11: Check Yes Do the radiator main fans and Radiator main fan radiator sub fans rotate at high system is normal. speed? No Go to step 27.
Is the voltage 10 V or more?
Go to step 4.
Go to step 5.
Go to step 7.
Go to step 6.
Is the fuse blown out?
Replace the fuse.
Repair the power supply line.
Replace the fuse.
Is the resistance 1 M: or more?
Go to step 8.
Replace the sub fan relay. <Ref. to AC-41, Relay and Fuse.>
Is the resistance less than 1 :? Go to step 9.
Replace the sub fan relay. <Ref. to AC-41, Relay and Fuse.>
CO(H4SO)-9
Radiator Fan System

COOLING
Step CHECK HARNESS BETWEEN SUB FAN RELAY TERMINAL AND SUB FAN MOTOR CONNECTOR. 1) Disconnect the connector from the sub fan motor. 2) Measure the resistance of harness between the sub fan relay terminal and sub fan motor connector. Connector & terminal (F16) No. 2 (F27) No. 11: CHECK HARNESS BETWEEN SUB FAN MOTOR CONNECTOR AND MAIN FAN RELAY 2 CONNECTOR. 1) Remove the main fan relay 2 from the relay holder. 2) Measure the resistance of harness between sub fan motor connector and main fan relay 2 connector. Connector & terminal (F16) No. 1 (F27) No. 18: CHECK POOR CONTACT. Check poor contact of sub fan motor connector. Check Yes Is the resistance less than 1 :? Go to step 10. No Repair the open circuit of harness between sub fan relay terminal and sub fan motor connector.
10
Repair the open circuit of the harness between sub fan motor connector and main fan relay 2 connector.
11
12
Is there poor contact in the sub Repair the poor fan motor connector? contact of sub fan motor connector. CHECK SUB FAN MOTOR. Does the radiator sub fan Go to step 13. Connect the battery positive (+) terminal to ter- rotate? minal No. 2 of the sub fan motor, and the ground () terminal to terminal No. 1. Is the resistance less than 1 :? Go to step 14.
Go to step 12.
13
14
15
16
17
CHECK MAIN FAN RELAY 2. Measure the resistance of main fan relay 2. Terminals No. 21 No. 18: CHECK HARNESS BETWEEN MAIN FAN RELAY 2 AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 2 terminal and main fan motor connector. Connector & terminal (F17) No. 2 (F27) No. 21: CHECK MAIN FAN MOTOR AND GROUND CIRCUIT. Measure the resistance between main fan motor connector and chassis ground. Connector & terminal (F17) No. 1 Chassis ground: CHECK POOR CONTACT. Check poor contact of main fan motor connector. CHECK MAIN FAN MOTOR. Connect the battery positive (+) terminal to terminal No. 2 of the main fan motor, and the ground () terminal to terminal No. 1.
Replace the sub fan motor. <Ref. to CO(H4SO)-26, Radiator Sub Fan and Fan Motor.> Replace the main fan relay 2. <Ref. to AC-41, Relay and Fuse.> Repair the open circuit of the harness between main fan relay 2 terminal and main fan motor connector.
Is there poor contact in the main fan motor connector? Does the radiator main fan rotate?
Repair the poor contact of main fan motor connector. Go to step 18. Replace the main fan motor. <Ref. to CO(H4SO)-24, Radiator Main Fan and Fan Motor.>
Repair the open circuit of the harness between main fan motor connector and chassis ground. Go to step 17.
CO(H4SO)-10
Radiator Fan System

COOLING
Step Check Yes CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 :? Go to step 19. LAY AND ECM. 1) Disconnect the connectors from ECM. 2) Measure the resistance between the sub fan relay terminal and ECM connector. Connector & terminal (B136) No. 18 (F27) No. 12: CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check for poor contact of the ECM connector. connector? contact of ECM connector. No Repair the open circuit of harness between sub fan relay terminal and ECM.
18
19
20
21
22
23
24
25
26
CHECK MAIN FAN RELAY 1. 1) Turn the ignition switch to OFF. 2) Remove main fan relay 1 from the main fuse box. 3) Measure the resistance of terminal in main fan relay 1 switch. CHECK MAIN FAN RELAY 1. 1) Connect the main fan relay 1 coil side terminal to the battery. 2) Measure the resistance between terminals of main fan relay 1 switch. CHECK HARNESS BETWEEN MAIN FAN RELAY 1 AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 1 terminal and main fan motor connector. Connector & terminal (F17) No. 2 (F36) No. 6: CHECK HARNESS BETWEEN MAIN FAN RELAY 1 AND ECM. 1) Disconnect the connectors from ECM. 2) Measure the resistance between main fan relay 1 terminal and ECM connector. Connector & terminal (B136) No. 29 (B143) No. 7: CHECK HARNESS BETWEEN MAIN FAN RELAY 2 AND ECM. Measure the resistance between main fan relay 2 terminal and ECM connector. Connector & terminal (B136) No. 29 (F27) No. 22: CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 4 and 26. 3) Check the condition of fuse. CHECK POOR CONTACT. Check for poor contact of the ECM connector.
Go to step 21.
Check the DTC. Repair the trouble cause. <Ref. to EN(H4SO)(diag)40, Read Diagnostic Trouble Code (DTC).> Replace the main fan relay 1. <Ref. to AC-41, Relay and Fuse.>
Replace the main fan relay 1. <Ref. to AC-41, Relay and Fuse.> Repair the open circuit of the harness between main fan relay 1 terminal and main fan motor connector.
Repair the open circuit of the harness between main fan relay 1 terminal and ECM.
Repair the open circuit of the harness between main fan relay 2 terminal and ECM. Go to step 26.
Replace the fuse.
Is there poor contact in ECM connector?
27
CHECK OPERATION OF RADIATOR FAN. Does the radiator sub fan If the both fans do not rotate at high speed in the rotate? condition of step 2, check whether the radiator sub fan is rotating.
Repair the poor contact of ECM connector. Go to step 20.
Repair the power supply circuit to the main fuse box. Go to step 28.
CO(H4SO)-11
Radiator Fan System

COOLING
Step CHECK GROUND CIRCUIT OF MAIN FAN RELAY 2. 1) Remove the main fan relay 2 from A/C relay holder. 2) Measure the resistance between main fan relay 2 terminal and chassis ground. Connector & terminal (F27) No. 19 Chassis ground: CHECK POWER SUPPLY TO MAIN FAN RELAY 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between main fan relay 2 terminal and chassis ground. Connector & terminal (F27) No. 20 (+) Chassis ground (): CHECK MAIN FAN RELAY 2. 1) Turn the ignition switch to OFF. 2) Remove the main fan relay 2. 3) Measure the resistance of main fan relay 2. Terminals (F27) No. 18 (F27) No. 19: CHECK MAIN FAN RELAY 2. 1) Connect the battery to terminals No. 20 and No. 22 of the main fan relay 2. 2) Measure the resistance of main fan relay 2. Terminals (F27) No. 18 (F27) No. 19: Check Yes Is the resistance less than 1 :? Go to step 29. No Repair the open circuit of harness between main fan relay 2 and chassis ground.
28
29
Go to step 30.
30
Go to step 31.
Replace the main fan relay 2. <Ref. to AC-41, Relay and Fuse.>
31
Replace the main fan relay 2. <Ref. to AC-41, Relay and Fuse.>
CO(H4SO)-12
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Remove the drain plug (A) to drain engine coolant into container. NOTE: Remove the radiator cap so that engine coolant will drain faster.
3) Fill engine coolant into the reservoir tank up to FULL level.
FULL
FULL
LOW
LOW
CO-00269
(A)
CO-02096
5) Install the drain plug. 6) Install the under cover.
2. FILLING OF ENGINE COOLANT

1) Pour cooling system conditioner through the filler neck. Cooling system protective agent: Refer to SPECIFICATION for the cooling system protective agent. <Ref. to CO(H4SO)2, SPECIFICATION, General Description.> 2) Pour engine coolant into the radiator up to the filler neck position. Recommended engine coolant: Refer to SPECIFICATION for the recommended engine coolant. <Ref. to CO(H4SO)2, SPECIFICATION, General Description.> Amount of engine coolant: Refer to SPECIFICATION for the amount of engine coolant. <Ref. to CO(H4SO)-2, SPECIFICATION, General Description.> Engine coolant concentration: Refer to ADJUSTMENT for the engine coolant concentration. <Ref. to CO(H4SO)-14, ADJUSTMENT, Engine Coolant.> NOTE: The SUBARU Super Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum cylinder block. Always use SUBARU Super Coolant since other coolants may cause corrosion.
4) Close the radiator cap and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.) 5) Wait for one minute after the engine stops, open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position. 6) Perform the procedures 4) and 5) again. 7) Attach the radiator cap and reservoir tank cap properly. 8) Start the engine and operate the heater at maximum hot position and the blower speed setting to LO 9) Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: Be careful with the engine coolant temperature gauge to prevent overheating. 10) Stop the engine and wait until the engine coolant temperature drops to 30C (86F) or less. 11) Open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position. 12) Attach the radiator cap correctly. 13) Set the heater setting to maximum hot position and the blower speed setting to LO and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard at this time, perform the procedures from 9) again.
CO(H4SO)-13
Engine Coolant
COOLING
B: ADJUSTMENT
1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION
CAUTION: SUBARU Super Coolant concentration must be used from 50 to 60% to assure the best performance of the anti-freeze and anti-rust agents. To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper SUBARU Super Coolant concentration in the table, and add diluting water to the SUBARU Super Coolant (concentrated type) until it reaches the proper dilution.
Recommended Engine Coolant and Water for Dilution: Refer to SPECIFICATION for the recommended engine coolant and diluting water. <Ref. to CO(H4SO)-2, SPECIFICATION, General Description.>
CO(H4SO)-14
Water Pump
COOLING
4. Water Pump
A: REMOVAL
1) Remove the radiator. <Ref. to CO(H4SO)-19, REMOVAL, Radiator.> 2) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> 3) Remove the crank pulley. <Ref. to ME(H4SO)41, REMOVAL, Crank Pulley.> 4) Remove the timing belt cover. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> 5) Remove the timing belt. <Ref. to ME(H4SO)-44, TIMING BELT, REMOVAL, Timing Belt.> 6) Remove the automatic belt tension adjuster.
12) Remove the water pump.
CO-00021
CO-00016
7) Remove the camshaft position sensor. <Ref. to FU(H4SO)-24, REMOVAL, Camshaft Position Sensor.> 8) Remove the cam sprocket LH. <Ref. to ME(H4SO)-49, REMOVAL, Cam Sprocket.> 9) Remove the belt cover No. 2 LH.
CO-00019
CO-00020
11) Disconnect the hose from water pump.
CO(H4SO)-15
Water Pump
COOLING
B: INSTALLATION
1) Install the water pump onto cylinder block LH. NOTE: Use a new gasket. When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: First 12 Nm (1.2 kgf-m, 8.9 ft-lb) Second 12 Nm (1.2 kgf-m, 8.9 ft-lb)
(B) (C) (A) (D)
6) Install the camshaft position sensor. <Ref. to FU(H4SO)-24, INSTALLATION, Camshaft Position Sensor.> 7) Install an automatic belt tension adjuster with the tension rod held by a pin. <Ref. to ME(H4SO)-45, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.> 8) Install the timing belt. <Ref. to ME(H4SO)-46, TIMING BELT, INSTALLATION, Timing Belt.> 9) Install the timing belt cover. <Ref. to ME(H4SO)43, INSTALLATION, Timing Belt Cover.> 10) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.> 11) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.> 12) Install the radiator. <Ref. to CO(H4SO)-20, INSTALLATION, Radiator.>
(E)
(F)
C: INSPECTION
1) Check the water pump bearing for smooth rotation. 2) Check the water pump pulley for abnormalities. 3) Make sure the impeller is not abnormally deformed or damaged. 4) Inspect the clearance between impeller and pump case. Clearance between impeller and pump case: Standard 0.5 1.5 mm (0.020 0.060 in)
ME-02463
2) Install the hose to water pump. 3) Install the tensioner bracket. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
CO-00020
4) Install the belt cover No. 2 LH. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
CO-00293
5) After water pump installation, check pulley shaft for engine coolant leaks or noise. If leaks or noise are noted, replace the water pump assembly.
CO-00019
5) Install the cam sprocket LH. <Ref. to ME(H4SO)-49, INSTALLATION, Cam Sprocket.>
CO(H4SO)-16
Thermostat
COOLING
5. Thermostat
A: REMOVAL
1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine coolant completely. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 5) Disconnect the radiator outlet hose from thermostat cover.
B: INSTALLATION
1) Install a gasket to thermostat. NOTE: Use a new gasket. 2) Install the thermostat and thermostat cover. NOTE: Install with the jiggle pin facing upward. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
CO-00270
6) Remove the thermostat cover, and then remove the gasket and thermostat.
T
(D)
(C) (B)
(A) CO-02337
(A) (B) (C) (D)
Thermostat cover Gasket Thermostat Jiggle pin
(C) (B)
(A) CO-02336
3) Connect the radiator outlet hose to thermostat cover. 4) Install the under cover. 5) Lower the vehicle. 6) Fill engine coolant. <Ref. to CO(H4SO)-13, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
(A) Thermostat cover (B) Gasket (C) Thermostat
CO(H4SO)-17
Thermostat
COOLING
C: INSPECTION
Replace the thermostat if the valve does not close completely at an ambient temperature or if any malfunction is detected by the following test. Inspection method Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for even temperature distribution. The measured value should meet the specification. NOTE: Leave the thermostat in the boiling water for five minutes or more before measuring valve lift. Hold the thermostat with a wire or the like to avoid contacting with container bottom. Opening start temperature: 80 84C (176 183F) Full open temperature: 95C (203F) Total valve lift: 9.0 mm (0.354 in) or more
(A)
(B)
CO-02420
(A) Thermometer (B) Thermostat
CO(H4SO)-18
Radiator
COOLING
6. Radiator
A: REMOVAL
CAUTION: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery.
7) Disconnect the connectors of radiator main fan motor connector (A) and radiator sub fan motor connector (B).
(A)
CO-02097
IN-00203
3) Lift up the vehicle. 4) Remove the under cover. 5) Remove the heat shield cover from radiator. (AT model)
(B)
CO-02466
8) Disconnect the radiator outlet hose from thermostat cover.
CO-02355
6) Drain engine coolant completely. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO-00270
9) Disconnect the ATF cooler hoses from ATF pipes. (AT model) NOTE: Plug the ATF pipe to prevent ATF from leaking.
CO-00253
10) Lower the vehicle. 11) Disconnect the over flow hose. 12) Remove the reservoir tank. <Ref. CO(H4SO)-28, REMOVAL, Reservoir Tank.>
to
CO(H4SO)-19
Radiator
COOLING
13) Remove the hood stay holder.
B: INSTALLATION
1) Attach the radiator lower cushion to the hole on the radiator lower bracket.
CO-00276
14) Remove the air intake duct. <Ref. to IN(H4SO)8, REMOVAL, Air Intake Duct.> 15) Disconnect the radiator inlet hoses from the engine.
CO-00041
2) Install the radiator to vehicle. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side. 3) Install the radiator upper brackets and tighten the bolts. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
CO-00277
16) Remove the radiator upper brackets.
CO-00278
4) Connect the radiator inlet hose.
CO-00278
17) Lift the radiator up and away from vehicle.
CO-00277
5) Install the air intake duct. <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Duct.>
CO(H4SO)-20
Radiator
COOLING
6) Install the hood stay holder. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
12) Connect the radiator main fan motor connector (A) and radiator sub fan motor connector (B).
(A)
CO-02097 CO-00276
7) Install the reservoir tank. <Ref. to CO(H4SO)28, INSTALLATION, Reservoir Tank.> 8) Connect the over flow hose. 9) Lift up the vehicle. 10) Connect the ATF cooler hoses. (AT model)
(B)
CO-02466
13) Install the heat shield cover. (AT model) Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb)
CO-00253
11) Connect the radiator outlet hose.
CO-02355
14) Install the under cover. 15) Lower the vehicle. 16) Connect the ground cable to battery.
CO-00270
IN-00203
17) Fill engine coolant. <Ref. to CO(H4SO)-13, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 18) Check the ATF level. (AT model) <Ref. to 4AT26, INSPECTION, Automatic Transmission Fluid.>
CO(H4SO)-21
Radiator
COOLING
C: INSPECTION
1) Remove the radiator cap, fill the radiator with engine coolant, and then install the tester to the installation position of cap.
CO-02475
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi) to the radiator and check the following points: Leakage from the radiator or its vicinity Leakage from the hose or its connections CAUTION: Engine should be turned off. Wipe engine coolant from check points in advance. Be careful of engine coolant from spurting out when removing the tester. Be careful not to deform the filler neck of radiator when installing and removing the tester.
CO(H4SO)-22
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
CO-00044
2) Increase pressure until the tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Replace the cap if it is opened under a pressure less than the service limit value. Standard: 93 123 kPa (0.95 1.25 kg/cm2, 14 18 psi) Service limit: 83 kPa (0.85 kg/cm2, 12 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.
CO(H4SO)-23
Radiator Main Fan and Fan Motor

COOLING
8. Radiator Main Fan and Fan Motor

A: REMOVAL
12) Disconnect the radiator inlet hoses from the engine.
CO-00277
13) Remove the bolts which hold the radiator main fan shroud to the radiator.
IN-00203
3) Lift up the vehicle. 4) Remove the under cover. 5) Disconnect the connector (A) of the radiator main fan motor.
CO-00096
14) Remove the radiator main fan motor assembly.

(A)
CO-02097
6) Remove the heat shield cover. (AT model)
CO-02355
7) Remove the ATF hose from the clip of the radiator main fan motor assembly. (AT model) 8) Lower the vehicle. 9) Disconnect the over flow hose. 10) Remove the reservoir tank. <Ref. to CO(H4SO)-28, REMOVAL, Reservoir Tank.> 11) Drain approximately 2.0 2 of coolant. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO(H4SO)-24

COOLING
B: INSTALLATION
Install in the reverse order of removal. NOTE: If the installation of the radiator main fan motor assembly is difficult, attempt installation after loosening the bolts which hold the radiator sub fan motor assembly. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
3) Remove the bolts which hold fan motor onto shroud.
CO-00098
D: ASSEMBLY
Assemble in the reverse order of disassembly. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
CO-00096
CO-00098
CO-02355
C: DISASSEMBLY
1) Remove the clip which holds motor connector onto the shroud. 2) Remove the nuts which hold the fan to the fan motor.
CO-00102
CO-00102
CO(H4SO)-25
Radiator Sub Fan and Fan Motor

COOLING
9. Radiator Sub Fan and Fan Motor

A: REMOVAL
11) Disconnect the radiator inlet hoses from the engine.
CO-00277
12) Remove the bolts which hold the radiator sub fan shroud to the radiator.
IN-00203
3) Lift up the vehicle. 4) Remove the under cover. 5) Remove the connector (B) of radiator sub fan motor.
CO-00101
13) Remove the radiator sub fan motor assembly from underneath the vehicle.
(B)
CO-02466
6) Remove the heat shield cover. (AT model)
CO-02355
7) Remove the ATF hose from the clip of the radiator sub fan motor assembly. (AT model) 8) Lower the vehicle. 9) Remove the air intake duct (rear). <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Duct.> 10) Drain approximately 2.0 2 of coolant. <Ref. to CO(H4SO)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO(H4SO)-26

COOLING
B: INSTALLATION
C: DISASSEMBLY
1) Remove the clip which holds the fan motor connector to the shroud. 2) Remove the nuts which hold the fan motor.
CO-00101
CO-00097
3) Remove the bolts which hold fan motor onto shroud.
CO-00098 CO-02355
D: ASSEMBLY
CO-00098
CO-00097
CO(H4SO)-27
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose connecting to the radiator from the reservoir tank. 2) Push in the hook (A), and pull the reserve tank in the direction of the arrow to remove.
(A)
CO-00279
B: INSTALLATION
C: INSPECTION
Make sure the engine coolant level is between FULL and LOW.
CO(H4SO)-28
Engine Cooling System Trouble in General

COOLING
11.Engine Cooling System Trouble in General

A: INSPECTION
Trouble Possible cause a. Insufficient engine coolant b. Loose timing belt c. Oil on timing belt d. Malfunction of thermostat e. Malfunction of water pump f. Clogged engine coolant passage g. Improper ignition timing Overheating h. Clogged or leaking radiator i. Engine oil mixed in engine coolant j. Air/fuel mixture ratio too lean k. Excessive back pressure in exhaust system l. Insufficient clearance between piston and cylinder m. Slipping clutch n. Dragging brake o. Defective radiator fan Over-cooling a. Ambient temperature extremely low b. Defective thermostat a. Loosened or damaged connecting units on hoses b. Leakage from water pump c. Leakage from water pipe d. Leakage around cylinder head gasket e. Damaged or cracked cylinder head and cylinder block f. Damaged or cracked thermostat cover g. Leakage from radiator a. Timing belt problem b. Defective radiator fan c. Defective water pump bearing d. Defective water pump mechanical seal Corrective action Replenish engine coolant, inspect for leakage, and repair it if necessary. Repair or replace timing belt tensioner. Replace. Replace. Replace. Clean. Inspect and repair ignition control system. <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Clean, repair or replace. Replace the engine coolant. If defective is not improved, check, repair and replace the engine parts. Inspect and repair the fuel injection system. <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.> Clean or replace. Adjust or replace. Repair or replace. Adjust. Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them. Partly cover radiator front area. Replace. Repair or replace. Replace. Repair or replace. Retighten cylinder head bolts or replace gasket. Repair or replace. Repair or replace. Repair or replace. Replace. Replace. Replace water pump. Replace water pump.
Engine coolant leaks
Noise
CO(H4SO)-29

COOLING
CO(H4SO)-30
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method Pump type Number of teeth Inner rotor Outer rotor mm (in) Standard Standard Standard Discharge pressure Discharge rate Discharge pressure Discharge rate Non-turbo model Turbo model mm (in) mm (in) Forced lubrication Trochoid type 9 10 76 10 (2.99 0.39) 78 10 (3.07 0.39) 0.04 0.14 (0.0016 0.0055) 0.02 0.07 (0.0008 0.0028)
Outer rotor diameter thickness Tip clearance between inner and outer rotors Side clearance between inner rotor and pump case Case clearance between outer rotor and pump case
Oil pump
mm (in) 0.10 0.175 (0.0039 0.0069) kPa (kg/cm2, psi) 2 (US qt, Imp qt)/min. kPa (kg/cm2, psi) 2 (US qt, Imp qt)/min. kPa (kg/cm2, psi) 98 (1.0, 14) 4.6 (4.9, 4.0) or more 294 (3.0, 43) 47.0 (49.7, 41.4) or more 588 (6.0, 85) Full-flow filter type 800 (124) 555 (86) 160 (1.63, 23.2) 68 65 (2.68 2.56) 67.4 65.3 (2.65 2.57) M 20 1.5 Immersed contact point type 12 V 3.4 W or less 14.7 (0.15, 2.1) 981 (10, 142) or more 5.0 (5.3, 4.4) Non-turbo model: 4.2 (4.4, 3.7) Turbo model: 4.3 (4.5, 3.8) 4.0 (4.2, 3.5)
600 rpm Performance (Oil temperature 80C (176F)) 5,000 rpm
Relief valve working pressure Filter type
Oil filter
Oil pressure switch
Outer diameter: 68 mm (2.68 in) (Black) Outer diameter: 67.4 mm (2.65 in) (Blue) By-pass valve opening pressure kPa (kg/cm2, psi) Outer diameter: 68 mm (2.68 in) (Black) Outer diameter mm (in) width Outer diameter: 67.4 mm (2.65 in) (Blue) Installation screw specifications Type Operating voltage power consumption Warning light operating pressure kPa (kg/cm2, psi) Proof pressure kPa (kg/cm2, psi) Total capacity (Overhaul) 2 (US qt, Imp qt) Filtration area cm2 (sq in) When replacing engine oil and oil filter When replacing engine oil only 2 (US qt, Imp qt) 2 (US qt, Imp qt)
Engine oil
LU(H4SO)-2
General Description
LUBRICATION
Recommended oil: Oil complying with one of the following standards: For API standard, oil with SM Energy Conserving logo For ILSAC standard, oil with GF-4 Star burst mark label on the container
SAE (1) ( C) -30 -20 -15 ( F) -22 -4 5
0 32
15 59
30
40
86 104
10W-30, 10W-40 , 10W-50 5W-30 (2)
LU-02329
(1) SAE viscosity No. and applicable temperature (2) Recommended
CAUTION: It is acceptable to fill an engine with oil of another brand when replacing the oil, but make sure to use an oil with an API standard and SAE viscosity number specified by Subaru. NOTE: The proper viscosity oil helps the engine maintain its ideal temperature, and cranking speed increased by reducing viscosity friction in hot condition. If the vehicle is used in regions of high temperatures or in other severe environments, use oil with the viscosities shown below. API standard: SM or SL SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W50
LU(H4SO)-3
General Description
LUBRICATION
B: COMPONENT
NON-TURBO MODEL
T4 (13)
(16) (15) (12) (14) T2 (11) T2 (18) T2 (29) (28) (17)
T2 T8 (9) (8) T7 (6) (7) T6 (19) (31) (20) T2 T3 (10) (5) (4) (2) (27) T2 (24) T2 (30) (32)
(3)
(1)
T5
T1
(22) (21) (23) (26) (25) T5 LU-02471
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Plug Gasket Relief valve spring Relief valve Front oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Oil filter O-ring Oil pump ASSY Oil pressure switch Oil filler duct
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Gasket Oil filler cap O-ring Baffle plate O-ring Oil strainer Oil level gauge guide O-ring Oil pan Oil level gauge Drain plug Drain plug gasket Gasket Seal
(29) (30) (31) (32)
Rocker cover O-ring Oil filter connector Plug
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 6.4 (0.7, 4.7) T3: 10 (1.0, 7.4) T4: 25 (2.5, 18.4) T5: 44 (4.5, 32.5) T6: 5.4 (0.6, 4.0) T7: 45 (4.6, 33.2) T8: 70 (7.1, 51.6)
LU(H4SO)-4
General Description
LUBRICATION
TURBO MODEL
T5 (16) (30) (33) T3 (17)
(15)
(18)
(14) T3 (29) T3 (20)
(31) (19)
T3 T2 (9) (35) (8) (6) (7) (12) T4 (13) (22) T3 (23) T3 (34) (5) (4) (2) (11) T7 T3 (32) (3) (1) T6 (10) T1 (27) T6 LU-02422 (28) (24) (25) (21) (26) T8
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)
Plug Gasket Relief valve spring Relief valve Front oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Oil filter Oil cooler connector Water by-pass pipe Oil cooler O-ring Oil pump ASSY
(16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)
Oil pressure switch Oil filler duct O-ring Rocker cover Baffle plate O-ring Oil strainer Gasket Oil level gauge guide Oil pan Oil level gauge Drain plug gasket Drain plug Gasket Oil filler cap
(31) (32) (33) (34) (35)
Seal O-ring Gasket O-ring Nipple
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 5.4 (0.6, 4.0) T3: 6.4 (0.7, 4.7) T4: 10 (1.0, 7.4) T5: 25 (2.5, 18.4) T6: 44 (4.5, 32.5) T7: 54 (5.5, 39.8) T8: 69 (7.0, 50.9)
LU(H4SO)-5
General Description
LUBRICATION
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. Prepare a container and cloth to prevent scattering of oil when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. Follow all government and local regulations concerning disposal of refuse when disposing oil.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 18332AA000 DESCRIPTION OIL FILTER WRENCH REMARKS Used for removing and installing oil filter (Black). (Outer diameter: 68 mm (2.68 in))
ST18332AA000
499587100
OIL SEAL INSTALLER
Used for installing oil seal into oil pump.
ST-499587100
2. GENERAL TOOL
TOOL NAME Oil filter wrench (65/67 mm 14 Flutes) REMARKS Used for removing and installing oil filter (Blue). (Outer diameter: 67.4 mm (2.65 in))
LU(H4SO)-6
Oil Pressure System

LUBRICATION
2. Oil Pressure System

A: WIRING DIAGRAM
B72 No. 5 1 3 IGNITION SWITCH SBF-6 MAIN SBF BATTERY
OIL PRESSURE WARNING LIGHT
A3
COMBINATION METER A: i10
A15 i3 17 B38 B21
E2
*
E11
: TURBO MODEL EXCEPT FOR TURBO MODEL
: 45 : 31
E
OIL PRESSURE SWITCH
B21 B72 A: i10 B38
1 2 3 4 5 6
6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
LU-02478
LU(H4SO)-7
Oil Pressure System

LUBRICATION
B: INSPECTION
1 Step Check CHECK COMBINATION METER. Does the warning light illumi1) Turn the ignition switch to ON (engine OFF). nate? 2) Check other warning lights. Yes Go to step 2. No Repair or replace the combination meter. <Ref. to IDI5, INSPECTION, Combination Meter System.> Go to step 3.
CHECK THE HARNESS CONNECTOR BEIs the voltage 10 V or more? TWEEN THE COMBINATION METER AND THE OIL PRESSURE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from oil pressure switch. 3) Turn the ignition switch to ON. 4) Measure the voltage of harness between oil pressure switch connector and chassis ground. Connector & terminal (E11) No. 1 (+) Chassis ground (): CHECK COMBINATION METER. Is the resistance less than 10 :? 1) Turn the ignition switch to OFF. 2) Remove the combination meter. 3) Measure the resistance of combination meter. Terminals (i10) No. 3 No. 15:
Replace the oil pressure switch.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between combination meter and oil pressure switch Poor contact in combination meter connector Poor contact of coupling connector
Repair or replace the combination meter. <Ref. to IDI5, INSPECTION, Combination Meter System.>
LU(H4SO)-8
Engine Oil
LUBRICATION
3. Engine Oil
A: INSPECTION
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe away the oil. 3) Reinsert the oil level gauge all the way. Be sure that the oil level gauge is correctly inserted and properly orientated. 4) Pull out the oil level gauge again, and check the oil level. If the engine oil level is below L line, check for oil leakage from engine and add oil to bring the level up to the F line. 5) Start the engine and warm it up for a time. 6) After turning off the engine, wait a few minutes for the oil to return to the oil pan before checking the level. NOTE: Just after driving or while the engine is warm, engine oil level shows in the range between F line and cutout portion. This is caused by thermal expansion of engine oil. To prevent overfilling of engine oil, do not add oil above F line when the engine is cold. As the oil level gauge is used for daily maintenance, F line and L line is set assuming that the engine is cold. Non-turbo model
(A) (B) (F)
Turbo model
(B) (F) (C) (A) (E) (D)
PM-00367
(A) (B) (C) (D) (E) (F)
Oil level gauge Engine oil filler cap F line L line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) Notch mark
(C) (E) (D)
PM-00362
LU(H4SO)-9
Engine Oil
LUBRICATION
B: REPLACEMENT
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Set the vehicle on a lift. 2) Open the engine oil filler cap for quick draining of engine oil. 3) Lift up the vehicle. 4) Drain engine oil by loosening the engine oil drain plug. NOTE: Prepare the container for draining of engine oil.
8) Close the engine oil filler cap. 9) Start the engine, and spreads the oil in engine room. 10) After stopping the engine, recheck the oil level. If necessary, add engine oil up to the F line on oil level gauge. Non-turbo model
(A) (B) (F)
(C) (E) (D)
PM-00362
Turbo model
(B) (F) (C) PM-00323 (A) (E) (D)
5) Tighten the engine oil drain plug after draining engine oil. NOTE: Use a new drain plug gasket. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
(A) (B) (C) (D) (E) (F)
PM-00367
Oil level gauge Engine oil filler cap F line L line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) Notch mark
PM-00323
6) Lower the vehicle. 7) Using engine oil of proper quality and viscosity, fill engine oil through the oil filler duct to the F line on the level gauge. Make sure that the vehicle is parked on a level surface when checking oil level. Recommended oil: Refer to SPECIFICATION for the recommended oil. <Ref. to LU(H4SO)-2, SPECIFICATION, General Description.> Engine oil capacity: Refer to SPECIFICATION for the engine oil capacity. <Ref. to LU(H4SO)-2, SPECIFICATION, General Description.>
LU(H4SO)-10
Oil Pump
LUBRICATION
4. Oil Pump
A: REMOVAL
1) Set the vehicle on a lift. 2) Remove the collector cover. (Turbo model) 3) Disconnect the ground cable from battery.
13) Remove the bolts which install oil pump onto cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve before removing the oil pump.
IN-00203
LU-00015
4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the bolt (B) holding the oil cooler pipe to the oil pump. (Turbo model) 7) Remove the oil cooler pipe (A) and hose (C). (Turbo model)
14) Remove the oil pump by using flat tip screwdriver. CAUTION: Be careful not to scratch mating surfaces of cylinder block and oil pump.
(B)
(C) (A) (C) LU-00016 LU-02396
8) Lower the vehicle. 9) Remove the radiator. <Ref. to CO(H4SO)-19, REMOVAL, Radiator.> <Ref. to CO(H4DOTC)-20, REMOVAL, Radiator.> 10) Remove the crankshaft position sensor. <Ref. to FU(H4SO)-23, REMOVAL, Crankshaft Position Sensor.> <Ref. to FU(H4DOTC)-32, REMOVAL, Crankshaft Position Sensor.> 11) Remove the water pump. <Ref. to CO(H4SO)15, REMOVAL, Water Pump.> <Ref. to CO(H4DOTC)-20, REMOVAL, Radiator.> 12) Remove the crank sprocket. <Ref. to ME(H4SO)-50, REMOVAL, Crank Sprocket.> <Ref. to ME(H4DOTC)-57, REMOVAL, Crank Sprocket.>
15) Remove the front oil seal from the oil pump.
LU(H4SO)-11
Oil Pump
LUBRICATION
B: INSTALLATION
1) Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal.
4) Install the oil pump to cylinder block. Be careful not to damage the front oil seal during installation. NOTE: Make sure the front oil seal lip is not folded. Align the flat surface of oil pumps inner rotor with crankshaft before installation. Use new O-rings. Do not forget to install O-rings. 5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent
ST
LU-00021
2) Apply liquid gasket to the mating surfaces of oil pump. NOTE: Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
T LU-02103
(A)
ME-00165
(A) O-ring
3) Apply a coat of engine oil to the inside of front oil seal.
6) Install the crank sprocket. <Ref. to ME(H4SO)50, INSTALLATION, Crank Sprocket.> <Ref. to ME(H4DOTC)-57, INSTALLATION, Crank Sprocket.> 7) Install the water pump. <Ref. to CO(H4SO)-16, INSTALLATION, Water Pump.> <Ref. to CO(H4DOTC)-16, INSTALLATION, Water Pump.> 8) Attach the crankshaft position sensor. <Ref. to FU(H4SO)-23, INSTALLATION, Crankshaft Position Sensor.> <Ref. to FU(H4DOTC)-32, INSTALLATION, Crankshaft Position Sensor.> 9) Install the radiator. <Ref. to CO(H4SO)-20, INSTALLATION, Radiator.> <Ref. to CO(H4DOTC)21, INSTALLATION, Radiator.> 10) Lift up the vehicle. 11) Install the oil cooler pipe (A) and hose (C). (Turbo model)
ME-00312
LU(H4SO)-12
Oil Pump
LUBRICATION
12) Install the oil cooler pipe (A) to the oil pump using the bolt (B). (Turbo model) Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
C: DISASSEMBLY
Remove the screw which secures oil pump cover and then disassemble oil pump. Inscribe alignment marks on the inner and outer rotors so that they can be replaced in their original positions during reassembly. NOTE: Before disassembling the oil pump, remove the relief valve.
(B)
(C) (A) (C)
(E) (D)
LU-02396 (C)
(B)
(A) (F) (I)
(G) (H) IN-00203
16) Install the collector cover. (Turbo model)

LU-00020
(A) (B) (C) (D) (E) (F) (G) (H) (I)
Front oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Relief valve Relief valve spring Plug Gasket
LU(H4SO)-13
Oil Pump
LUBRICATION
D: ASSEMBLY
1) Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal.
5) Install the oil pump cover. Tightening torque: T1: 5.4 Nm (0.6 kgf-m, 4.0 ft-lb) T2: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
T1 (E) (D) (B) (C)
ST
LU-00021
(A) (F) (G)
2) Apply a coat of engine oil to inner and outer rotors. 3) Assemble the inner and outer rotors in their original positions. 4) Assemble the oil relief valve and install relief valve spring and plug. NOTE: Use a new gasket.
(A) (B) (C) (D) (E) (F) (G) (H) (I) Front oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Relief valve Relief valve spring Plug Gasket
(I)
(H)
T2
LU-02134
LU(H4SO)-14
Oil Pump
LUBRICATION
E: INSPECTION
1. TIP CLEARANCE
Measure the tip clearance of rotors. If the clearance is out of specification, replace the rotors as a set. Tip clearance: Standard 0.04 0.14 mm (0.0016 0.0055 in)
3. SIDE CLEARANCE
Measure the gap between the inner rotor and the oil pump case to measure the clearance between the oil pump inner rotor and the oil pump cover as shown in the figure. If the clearance is out of specification, replace the rotors or the oil pump case. Side clearance: Standard 0.02 0.07 mm (0.0008 0.0028 in)
LU-00023
2. CASE CLEARANCE
Measure the clearance between the outer rotor and the oil pump case. If clearance is out of standard, replace the oil pump case. Case clearance: Standard 0.10 0.175 mm (0.0039 0.0069 in)
LU-00025
4. OIL RELIEF VALVE

Check the valve for assembly condition and damage, and the relief valve spring for damage and deterioration. Replace the parts if defective. Relief valve spring: Free length 73.7 mm (2.902 in) Installed length 54.7 mm (2.154 in) Load when installed 93.1 N (9.49 kgf, 20.88 lbf)
5. OIL PUMP CASE

Check for worn shaft hole, clogged oil passage, worn rotor chamber, cracks and other faults.
LU-00024
6. FRONT OIL SEAL

Check the front oil seal lips for deformation, hardening, wear, etc. and replace if defective.
LU(H4SO)-15
Oil Pan and Strainer

LUBRICATION
5. Oil Pan and Strainer

A: REMOVAL
1) Set the vehicle on a lift. 2) Remove the collector cover. (Turbo model) 3) Disconnect the ground cable from battery.
10) Remove the hood stay holder (A) and radiator upper brackets (B).
(B)
(A)
(B) LU-00232
IN-00203
4) Remove the air intake duct. <Ref. to IN(H4SO)8, REMOVAL, Air Intake Duct.> <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 5) Disconnect the connector from the mass air flow and intake air temperature sensor. (Non-turbo model) 6) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 7) Remove the air intake boot. (Turbo model)
LU-00222
12) Lift up the vehicle. CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 13) Remove the under cover. 14) Drain the engine oil. <Ref. to LU(H4SO)-10, REPLACEMENT, Engine Oil.> 15) Remove the front exhaust pipe. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-5, REMOVAL, Front Exhaust Pipe.> 16) Remove the nuts which install the engine mounting onto the front crossmember.
LU-02397
8) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 9) Remove the pitching stopper.
ME-02650 AT-03877
17) Remove the bolts which install oil pan on cylinder block with the engine raised up.
LU(H4SO)-16

LUBRICATION
18) Insert the oil pan cutter blade into the gap between cylinder block and oil pan, and remove the oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter. 19) Remove the oil strainer. 20) Remove the baffle plate.
(D)
B: INSTALLATION
NOTE: Before installing the oil pan, clean the mating surface of oil pan and engine block. 1) Make sure that the seals (A) are installed securely on the baffle plate in a direction as shown in the figure below. NOTE: Use new seals.
(A)
(C) LU-00052 (B)
2) Install the baffle plate. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 3) Install the oil strainer to the cylinder block. NOTE: Use new O-rings.
LU-02334
(A)
(A) (B) (C) (D)
Oil pan Oil strainer Baffle plate Cylinder block
Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb) 4) Tighten the oil strainer stay together with the baffle plate. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 5) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: Use a new gasket. Install within 5 min. after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
(A) LU-02353
(A) Gasket
LU(H4SO)-17

LUBRICATION
6) Tighten the bolts which install oil pan to cylinder block. Tightening torque: T1: 5 Nm (0.5 kgf-m, 3.7 ft-lb) T2: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) T3: 10 Nm (1.0 kgf-m, 7.4 ft-lb)
(D)
Turbo model
(B) (A)
(A) (B) ME-03460
(C)
9) Install the front exhaust pipe. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-6, INSTALLATION, Front Exhaust Pipe.> 10) Install the under cover. 11) Lower the vehicle.
T2 T2
(B) T3 (A)
T1
CAUTION: When lowering the vehicle, lower the lift up device and wire ropes at the same time. 12) Remove the lifting device and wire ropes.
T1
LU-02335
(A) (B) (C) (D)
Oil pan Oil strainer Baffle plate Cylinder block
LU-00222
7) Lower the engine onto front crossmember. 8) Tighten the nuts which install engine mount onto front crossmember. NOTE: Make sure that the engine mount nuts (A) and locator (B) are securely installed. Tightening torque: 85 Nm (8.7 kgf-m, 62.7 ft-lb) Non-turbo model
T1
T2
AT-03878
(B)
(A)
(A)
(B)
ME-02651
LU(H4SO)-18

LUBRICATION
14) Install the hood stay holder (A) and radiator upper brackets (B). Tightening torque: (A): 7.5 Nm (0.8 kgf-m, 5.5 ft-lb) (B): 12 Nm (1.2 kgf-m, 8.9 ft-lb)
C: INSPECTION
Visually check that the oil pan, oil strainer and baffle plate are not damaged.
(B)
(A)
(B) LU-00232
15) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 16) Install the air intake boot. (Turbo model) Tightening torque: 2.5 Nm (0.3 kgf-m, 1.8 ft-lb)
LU-02397
17) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 18) Install the air intake duct. <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.> 19) Connect the connector to the mass air flow and intake air temperature sensor. (Non-turbo model) 20) Connect the ground cable to battery.
IN-00203
21) Install the collector cover. (Turbo model) 22) Refill the engine oil. <Ref. to LU(H4SO)-9, INSPECTION, Engine Oil.>
LU(H4SO)-19
Oil Pressure Switch

LUBRICATION
6. Oil Pressure Switch

A: REMOVAL
1) Remove the collector cover. (Turbo model) 2) Disconnect the ground cable from battery.
B: INSTALLATION
1) Apply liquid gasket to the oil pressure switch threads. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent
IN-00203
3) Remove the generator from the bracket. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 4) Disconnect the terminal from oil pressure switch.
LU-00038
2) Install the oil pressure switch to the cylinder block. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
LU-00036
5) Remove the oil pressure switch.

LU-00037
3) Connect the terminal to the oil pressure switch.
LU-00037
LU-00036
4) Install the generator to the bracket. <Ref. to SC(H4SO)-14, INSTALLATION, Generator.>
LU(H4SO)-20
Oil Pressure Switch

LUBRICATION
IN-00203
6) Install the collector cover. (Turbo model)
C: INSPECTION
Check the oil pressure switch installation portion for oil leakage and oil seepage.
LU(H4SO)-21
Engine Oil Cooler

LUBRICATION
7. Engine Oil Cooler

A: REMOVAL
CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: An engine oil cooler is installed on DOHC turbo models. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine coolant. <Ref. to CO(H4DOTC)14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 5) Remove the engine oil filter. <Ref. to LU(H4SO)23, REMOVAL, Engine Oil Filter.> 6) Remove the bolt (B) holding the oil cooler pipe (A) to the oil pump. 7) Remove the oil cooler pipe (A) and oil cooler hose (C). 8) Remove the oil cooler connector (D) and remove the oil cooler (E).
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: T1: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) T2: 54 Nm (5.5 kgf-m, 39.8 ft-lb)
(F)
(E) (C)
T2 (D)
(B)
T1
(A) LU-02399
(F)
(E) (C)
(A) (B) (C) (D) (E) (F)
Oil cooler pipe Bolt Oil cooler hose Oil cooler connector Oil cooler Gasket
C: INSPECTION
(D)
1) Check that coolant passages are not clogged using an compressed air. 2) Check the mating surfaces of cylinder block, gasket groove and oil cooler for damage.
(B) (A) LU-02398
(A) (B) (C) (D) (E) (F)
Oil cooler pipe Bolt Oil cooler hose Oil cooler connector Oil cooler Gasket
LU(H4SO)-22
Engine Oil Filter

LUBRICATION

A: REMOVAL
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the service hole cover clip located on the under cover.
B: INSTALLATION
CAUTION: Do not tighten excessively, or oil may leak. 1) Clean the oil filter installation surface on cylinder block or oil cooler. 2) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install the oil filter turning it by hand, being careful not to damage the seal rubber. Tighten the oil filter (Black) with an outer diameter of 68 mm (2.68 in) (approx. 1 rotation) after the seal rubber of the oil filter comes in contact with cylinder block or oil cooler. When using a torque wrench, tighten to 14 Nm (1.4 kgf-m, 10.3 ft-lb). Tighten the oil filter (Blue) with an outer diameter of 67.4 mm (2.65 in) (approx. 7/8 rotation) after the seal rubber of the oil filter comes in contact with cylinder block or oil cooler. When using a torque wrench, tighten to 12 Nm (1.2 kgf-m, 8.9 ft-lb). 4) Return the service hole cover to the original position. 5) Lower the vehicle.
LU-02190
4) Rotate the service hole cover in the arrow direction.
C: INSPECTION
1) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 2) Check the engine oil level. <Ref. to LU(H4SO)-9, INSPECTION, Engine Oil.>
LU-02191
5) Remove the oil filter. Oil filter (Black) Remove using the ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in) for oil filter (black)) Oil filter (Blue) Remove using a general tool (65/67 mm 14 Flutes).
(A)
LU-02192
LU(H4SO)-23
Engine Lubrication System Trouble in General

LUBRICATION
9. Engine Lubrication System Trouble in General

A: INSPECTION
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Trouble Possible cause Cracked diaphragm or oil leakage within switch Broken spring or seized contacts Clogging of oil filter Malfunction of oil by-pass valve in oil filter Malfunction of oil relief valve in oil pump 2) Low oil pressure Clogged oil passage Excessive tip clearance and side clearance of oil pump rotor and gear Clogged oil strainer or broken pipe Insufficient engine oil (including deterioration) 3) No oil pressure Broken pipe of oil strainer Stuck oil pump rotor 1) Malfunction of combination meter 2) Poor contact of switch contact points 3) Disconnection of wiring 1) Poor contact of terminals 2) Defective wiring harness 1) Oil pressure switch failure 3) Low oil pressure Corrective action Replace. Replace. Replace. Clean or replace. Clean or replace. Clean. Replace. Clean or replace. Replace. Replace. Replace. Replace. Replace. Repair. Repair. Repair. Check for the same possible causes as listed 1. 2.
1. Warning light remains ON.
2. Warning light does not illuminate.
3. Warning light flickers momentarily.
LU(H4SO)-24
General Description
SPEED CONTROL SYSTEMS
A: SPECIFICATION
Accelerator pedal Stroke At pedal pad 54 59 mm (2.13 2.32 in)
B: COMPONENT
(2) (1) T
(5) T
T (4) (3)
SP-02049
(1) (2) (3)
Accelerator pedal ASSY Clip Accelerator plate
(4) (5)
Accelerator stopper Accelerator pedal bracket
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal or installation. Keep the parts in order and protect them from dust and dirt. Before removal or installation, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.
SP(H4SO)-2
Accelerator Pedal
2. Accelerator Pedal
A: REMOVAL
IN-00203
2) Disconnect the connector (A). 3) Remove the nut (B) securing accelerator pedal assembly.
(A)
(B)
SP-02050
B: INSTALLATION
C: DISASSEMBLY
NOTE: The accelerator pedal cannot be disassembled.
D: INSPECTION
1) Check for smooth operation when the accelerator pedal is depressed. 2) Check if the accelerator pedal returns to its original position smoothly when the pedal is released.
SP(H4SO)-3
Accelerator Pedal
SP(H4SO)-4
General Description
IGNITION
A: SPECIFICATION
Item Ignition coil & ignitor assembly Type Manufacturer Secondary coil resistance Manufacturer and type Thread size (diameter, pitch, length) Spark plug gap Electrode Specification FH 0363 Diamond Electric 11.2 k:r15% NGK: FR5AP-11 14, 1.25, 19 1.0 1.1 (0.039 0.043) Platinum
Spark plug
mm mm (in)
B: COMPONENT
(3) T1
(2)
(2) (4) (4)
T2
(1)
IG-02078
(1) (2) (3)
Spark plug Spark plug cord (#1, #3) Ignition coil and ignitor ASSY
(4)
Spark plug cord (#2, #4)
IG(H4SO)-2
General Description
IGNITION
C: CAUTION
IG(H4SO)-3
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
Spark plug: Refer to SPECIFICATION for the spark plug. <Ref. to IG(H4SO)-2, SPECIFICATION, General Description.>
2. LH SIDE
1) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 2) Remove the spark plug cords by pulling the boot. (Do not pull the cord itself.)
1. RH SIDE
IG-02049
IN-00203
2) Remove the air cleaner case. <Ref. to IN(H4SO)-5, REMOVAL, Air Cleaner Case.> 3) Remove the spark plug cords by pulling the boot. (Do not pull the cord itself.)
IG-00022
B: INSTALLATION
1. RH SIDE
IG-00017
2. LH SIDE
IG-00018
IG(H4SO)-4
Spark Plug
IGNITION
C: INSPECTION
Check the electrodes and inner and outer ceramic insulator of plugs, noting the type of deposits and the degree of electrode erosion.
(A) (B)
3) Oil fouled: Wet black deposits show oil entrance into the combustion chamber through worn rings or pistons, or excessive clearance between valve guides and stems.
(C)
(D) (E) IG-00010 IG-00013
(A) (B) (C) (D) (E)
Spark plug gap Carbon accumulation or wear Cracks Damage Damaged gasket
4) Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicate engine overheating, incorrect ignition timing, wrong selection of fuel, and loose spark plugs.
1) Normal: Brown to grayish-tan deposits and slight electrode wear indicate correct spark plug heat range.
IG-00014
D: ADJUSTMENT
IG-00011
2) Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in the city, weak ignition, too rich fuel mixture and dirty air cleaner.
Clean spark plugs with a nylon brush, etc. Clean and remove the carbon or oxide deposits. If deposits are too stubborn, replace the spark plugs. After cleaning the spark plugs, measure the spark plug gap using a gap gauge. NOTE: Never use plug cleaner. Do not use metal brush or it will wear insulator. Spark plug gap L: 1.0 1.1 mm (0.039 0.043 in)
IG-00012
IG-02035
IG(H4SO)-5
Ignition Coil and Ignitor Assembly

IGNITION
3. Ignition Coil and Ignitor Assembly

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb) CAUTION: Connect the spark plug cords to correct positions. Failure to do so will damage the unit.
C: INSPECTION
Check the secondary coil resistance using a tester. Replace if defective. CAUTION: If the resistance is extremely low, it indicates the presence of a short-circuit. Ignitor is integrated with the coil. Therefore the resistance of primary side coil cannot be measured. Specified resistance: [Secondary side] Between (A) and (B) 11.2 k:r15% Between (C) and (D) 11.2 k:r15%
IN-00203
2) Disconnect the spark plug cords from ignition coil and ignitor assembly.
IG-02064
3) Disconnect the connector (A) from the ignition coil and ignitor assembly. 4) Remove the bolt (B) which secures the ignition coil and ignitor assembly to the intake manifold.
(B)
(C) (A)
(D) (B)
IG-02066 (A)
(B) IG-02065
IG(H4SO)-6
Spark Plug Cord

IGNITION
4. Spark Plug Cord

A: INSPECTION
Check the following items. Damage to cords, deformation, burning or rust formation of terminals Resistance value of cords Specified resistance: #1 cord: 7.1 12.1 k: #2 cord: 12.1 19.9 k: #3 cord: 7.7 13.0 k: #4 cord: 12.3 20.2 k:
IG-00102
IG(H4SO)-7
Spark Plug Cord

IGNITION
IG(H4SO)-8
General Description
STARTING/CHARGING SYSTEMS
A: SPECIFICATION
Item Vehicle model Type Model Manufacturer Voltage and output Direction of rotation Number of pinion teeth Voltage No-load Current characteristics Starter Rotating speed Voltage Current Load characteristics Torque Rotating speed Voltage Lock Current characteristics Torque Type 2.5 L Non-turbo, 2.5 L Turbo 3.0 L Non-turbo Manufacturer Voltage and output Polarity on ground side Direction of rotation Stator connection Output current Regulated voltage Type and capacity MT Reduction type 428000-4780 DENSO 12 V 1.6 kW 12 V 1.6 kW Counterclockwise (when observed from pinion) 9 9 11 V 11 V 90 A or less 90 A or less 1,900 rpm or more 1,900 rpm or more 8V 8V 370 A 370 A 11.1 Nm (1.1 kgf-m, 8.2 ft-lb) or more 11.1 Nm (1.1 kgf-m, 8.2 ft-lb) or more 910 rpm or more 910 rpm or more 3V 3V 750 A or less 750 A or less 15.5 Nm (1.6 kgf-m, 11.4 ft-lb) or more 15.5 Nm (1.6 kgf-m, 11.4 ft-lb) or more Rotating-field three-phase type, voltage regulator built-in type, with load response control system A3TG2391ZC A3TG0591 MITSUBISHI ELECTRIC 12 V 110 A Negative Clockwise (when observed from pulley side) 3-phase Y-type 1,500 rpm 50 A or more 2,500 rpm 91 A or more 5,000 rpm 105 A or more 14.1 14.8 V [20C (68F)] 12 V 48 AH (55D23L) 12 V 52 AH (75D23L) 428000-4790 Specification AT
Model
Generator
Battery
SC(H4SO)-2
General Description
B: COMPONENT
1. STARTER
T4 (18)
(10) (11) (9) (7) T2 (6) (5)
T3 (3) (8) (4) (2) (17) (14) (19) (13) (1) (12) (16) (15) T1
SC-02127
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Starter housing Snap ring Stopper Overrunning clutch Snap ring Shift lever Starter seal Shock absorber bearing Shock absorber
(10) (11) (12) (13) (14) (15) (16) (17)
Internal gear Shaft Planetary gear Starter plate Yoke Armature Brush holder ASSY Starter cover
(18) (19)
Magnet switch ASSY Drain duct
SC(H4SO)-3
General Description
2. GENERATOR
(7)
(6)
(5) (4) (3) T1 (2)
(1)
T1
T2 (13)
(12)
(11) (10) (9)
(8) SC-02121
(1) (2) (3) (4) (5) (6)
Pulley nut Pulley Front cover Ball bearing Bearing retainer Rotor
(7) (8) (9) (10) (11) (12)
Bearing Stator coil IC regulator with brush Brush Rectifier Rear cover
(13)
Terminal
SC(H4SO)-4
General Description
C: CAUTION
SC(H4SO)-5
Starter
2. Starter
A: REMOVAL
C: DISASSEMBLY
1) Loosen the nut which holds terminal M (A) of the magnet switch assembly, then disconnect the harness from the terminal.
(A)
IN-00203
SC-02128
2) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 3) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 4) Remove the air intake chamber stay LH. (2.5 L non-turbo model) 5) Disconnect the connector and terminal from starter.
(A)
2) Remove the nuts which secure the magnet switch assembly and remove the magnet switch assembly.
SC-02129
3) Remove the starter seal.

(B)
SC-02038
(A) Terminals (B) Connector
6) Remove the starter from transmission.
SC-02130
B: INSTALLATION
SC(H4SO)-6
Starter
4) Remove the through bolts on both sides, and remove the starter housing.
6) Remove the overrunning clutch, shock absorber bearing and shaft from the yoke as an assembly.
SC-02131
SC-02132
SC-02136
5) Remove the shift lever.
7) Remove the overrunning clutch from shaft assembly as follows: (1) Using a plastic hammer, remove the stopper from snap ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench).
(A)
SC-02133 (D)
(B) (C)
SC-02148
(A) (B) (C) (D)
Appropriate tool Snap ring Shaft Stopper
SC(H4SO)-7
Starter
(2) Remove the snap ring (A) from the shaft, and then remove the stopper (B).
(3) Remove the snap ring, and then remove the shaft.
(A)
(B)
SC-02134
SC-02137
(3) Remove the overrunning clutch from the shaft.
SC-02140 SC-02135
8) Remove the shock absorber as follows: (1) Remove the starter plate.
(4) Separate the shock absorber bearing (A) from the internal gear (B), and then remove the shock absorber (C).
(A)
(B)
(C) SC-02141 SC-02138
(2) Remove the planetary gear.
SC-02139
SC(H4SO)-8
Starter
9) Remove the screws, and remove the starter cover from the brush holder assembly. NOTE: Hold the screws down and separate the starter cover so that the brush holder assembly remains on the armature side.
D: ASSEMBLY
1) Install the armature to yoke.
SC-02145
2) Install the brush holder assembly to the armature.

SC-02142
NOTE: Spread the brush with your fingers, being careful not to damage the brush.
SC-02143
10) Remove the brush holder assembly from the armature. NOTE: Spread the brush with your fingers, being careful not to damage the brush.
SC-02144
3) Install the starter cover, and then secure it to the brush holder assembly with the screws.
SC-02142 SC-02144
11) Remove the armature from yoke.
SC-02145
SC(H4SO)-9
Starter
4) Assemble the shock absorber as follows: (1) Apply grease to the shock absorber (C), and install the internal gear (B) to the shock absorber bearing (A). NOTE: Align with the claw position of internal gear to install shock absorber bearing. Grease: DENSO HL50
(A)
5) Install the planetary gear to the internal gear. (1) Apply grease to the planetary gear attachment area. Grease: DENSO HL50 (2) Install the planetary gear to pin. (3) Apply grease to the planetary gear, internal gear and upper part of the pin. NOTE: Apply grease so that it contacts each gear. Be careful not to allow dirt to get in.
(B)
Grease: DENSO HL50
(C) SC-02141
(2) Install the shaft to the internal gear. NOTE: Apply grease to the sliding part for the shaft inside the internal gear. Grease: DENSO HL50 (4) Install the starter plate.
SC-02139
SC-02138 SC-02140
(3) Install the snap ring to shaft. NOTE: Use new snap rings.
6) Assemble the overrunning clutch as follows: (1) Apply grease to the spline portion of the shaft. Grease: DENSO HL50 (2) Install the overrunning clutch to shaft.
SC-02137 SC-02135
SC(H4SO)-10
Starter
(3) Install the stopper (B) to the shaft, and install the snap ring (A).
8) Install the shift lever. NOTE: Apply grease to the contact portion of the shift lever. Grease: DENSO HL50
(A)
(B)
SC-02134
(4) Press-fit the stopper (B) to snap ring (A) using a press.
(A) (B) SC-02133
9) Install the starter housing, and tighten the through bolts on both sides. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
SC-00068
7) Assemble the overrunning clutch, shock absorber and shaft to the yoke as one unit.
SC-02132
SC-02131
10) Install the starter seal.
SC-02136
SC-02130
SC(H4SO)-11
Starter
11) Install the magnet switch assembly to the starter housing, and tighten the nuts. NOTE: Apply grease to the installation part of the shift lever. Grease: DENSO HL50 Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
E: INSPECTION
1. SWITCH ASSEMBLY
Using a circuit tester (set to ohm), check that there is continuity between terminals S and M, and between terminal S and ground. Also check to be sure there is no continuity between terminal M and B. Terminal/Resistance: S M/1 : or less S Ground/1 : or less M B/1 M: or more
(C)
SC-02129
(A) (B) SC-00181
12) Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb)
(A) Terminal S (B) Terminal M (C) Terminal B
2. SWITCH ASSEMBLY OPERATION

(A)
SC-02128
NOTE: Test period of each test must be within short time (3 5 seconds). 1) Vacuum test Disconnect the harness from terminal M and connect it as shown in the figure. Make sure the pinion gear sticks out.
(B)
(A) SC-02086
(A) Terminal S (B) Terminal M
SC(H4SO)-12
Starter
2) Hold test Make sure the pinion gear remains stick out even after disconnecting terminal M in the above condition.
(B)
3. PERFORMANCE TEST
The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine. Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test. For these performance tests, use the circuit shown in figure.
(A) SC-02087 S B M (C) V A SC-00077 + 12V (B)
(A)
3) Return test Connect the positive terminal to terminal S and the negative terminal to terminal M and starter body to pull the pinion gear at the main contact point. Make sure the pinion gear returns to its original position when the terminal S is disconnected.
(B)
(A) Variable resistance (B) Magnetic switch (C) Starter body
1) No-load test With switch on, adjust the variable resistance until the voltage is 11 V, read the value of ammeter to measure rotating speed. Compare these values with the standard. No-load test (standard): Voltage/Current Max. 11 V/90 A or less Rotating speed 1,900 rpm or more 2) Load test Apply the specified braking torque to starter. The condition is satisfactory if the current draw and rotating speed are within specifications. Load test (standard): Voltage/Load 8 V/11.1 Nm (1.1 kgf-m, 8.2 ft-lb) Current/Speed 370 A/910 rpm or more 3) Lock test With the starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to standard voltage. Lock test (standard): Voltage/Current 3 V/750 A or less Torque 15.5 Nm (1.6 kgf-m, 11.4 ft-lb)
(A) SC-02088
SC(H4SO)-13
Generator
3. Generator
A: REMOVAL
Turbo model
ME-00830
4) Remove the bolts which install the generator onto bracket.

IN-00203
2) Remove the front side belts. <Ref. to ME(H4SO)-38, FRONT SIDE BELT, REMOVAL, V-belt.> or <Ref. to ME(H4DOTC)-41, FRONT SIDE BELT, REMOVAL, V-belt.> <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 3) Disconnect the connector and terminal from generator. 2.5 L Non-turbo model
SC-00179
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) CAUTION: Check and adjust the V-belt tension. <Ref. to ME(H4SO)-40, INSPECTION, V-belt.> <Ref. to ME(H4DOTC)-43, INSPECTION, V-belt.> <Ref. to ME(H6DO)-42, INSPECTION, V-belt.>
SC-00178
3.0 L Non-turbo model
SC-02003
SC-00179
SC(H4SO)-14
Generator
C: DISASSEMBLY
1) Remove the four through-bolts.
CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.
(A) (B)
SC-00078
(C) (D) SC-00036
2) Use a drier to heat the rear cover (A) portion to 50C (122F).
(A)
(A) (B) (C) (D)
Front cover Pulley Nut Rotor
5) Use the following procedures to remove the ball bearings. (1) Remove the bolt, and then detach the bearing retainer.
SC-00079
3) Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.
(A)
SC-00081
(A) SC-00080
(2) Firmly attach an appropriate tool (such as a correct size socket wrench) to the bearing inner race.
(A) Screwdriver
4) Using a vise, support the rotor and remove the pulley bolt.
SC-00082
(3) Use the press to push the ball bearings out from the front cover.
SC-00035
SC(H4SO)-15
Generator
6) Using the bearing puller, remove the bearings from the rotor.
(2) Disconnect the connection between the IC regulator and rectifier, then remove the IC regulator.
SC-00046
7) Disconnect the connection between the rectifier and stator coil, then remove the stator coil. CAUTION: The rectifier is easily damaged by heat. Do not allow a 180 270 W soldering iron to contact the terminals for 5 seconds or more at a time.
SC-00085
9) Use the following procedures to remove the brush. (1) Remove the cover A.
(A)
SC-00086
(A) Cover A
SC-00083
8) Use the following procedures to remove the IC regulator. (1) Remove the screws which secure the IC regulator to the rear cover.
(2) Remove the cover B.

(A)
SC-00087
(A) Cover B
SC-00084
(3) Disconnect the connection and remove the brush.
SC-00088
SC(H4SO)-16
Generator
10) Remove the rectifier as follows. (1) Remove the bolts which secure the rectifier.
D: ASSEMBLY
Assemble in the reverse order of disassembly. 1) Pull-out of the brush Before assembling, press the brush down into the brush holder, then fix the brush in that position by inserting a [1 mm (0.04 in) dia., 40 50 mm (1.6 2.0 in) long] wire through the hole as shown in the figure. CAUTION: After re-assembling, remove the wire.
SC-00089
(A)
(2) Remove the cover on terminal B.
SC-00092
(A) Wire
SC-00090
(3) Remove the nuts of terminal B, then remove the rectifier.
SC-00091
2) Install the ball bearings. (1) Set the ball bearings in the front cover, then securely install an appropriate tool (such as a socket wrench of proper size) to the bearing outer race. (2) Using a press to press the ball bearings into the specified location. (3) Install the bearing retainer. 3) Using a press to install the bearings (rear side) to the rotor shaft. 4) Heat the bearing box in rear cover [50 to 60C (122 to 140F)], and then press the rear bearing into rear cover. CAUTION: Do not apply grease to the rear bearings. If there is any oil on the bearing box, remove it completely. 5) After re-assembling, manually turn the pulley to check that the rotor rotates smoothly.
SC(H4SO)-17
Generator
E: INSPECTION
1. DIODE
CAUTION: There is the possibility of damaging the diodes if a mega-tester (used to measure high voltages) or a similar measuring instrument is used. Never use a mega tester or equivalent for this test. 1) Check the positive diode Check for continuity between the diode lead and positive side heat sink. If resistance is 1 : or less only in the direction from the diode lead to the heat sink, the positive diode is OK.
(A) (B)
2. ROTOR
1) Slip ring surface Inspect the slip rings for contamination or any roughness on the sliding surface. Repair the slip ring surface using a lathe or sand paper. 2) Slip ring outer diameter Measure the slip ring outer diameter. Replace the rotor assembly if the slip ring is worn. Slip ring outer diameter: Standard 22.7 mm (0.894 in) Limit 22.1 mm (0.870 in) 3) Continuity test Using a circuit tester, check the resistance between slip rings. If the resistance is not within the standard, replace the rotor assembly. Specified resistance: Approximately 1.6 1.9 :
SC-00042
(A) Diode lead (B) Heat sink (positive side)
2) Check negative diode Check for continuity between the negative side heat sink and diode lead. If resistance is 1 : or less only in the direction from the heat sink to the diode lead, the negative diode is OK.
(A)
SC-00044
4) Insulation test Check the continuity between slip ring and rotor core or shaft. If the resistance is 1 : or less, replace the rotor assembly because the rotor coil is grounded.
(B)
SC-00043
(A) Diode lead (B) Heat sink (negative side)

SC-00045
5) Ball bearings (rear side) Check the rear ball bearing. If there is any noise, or the rotor does not rotate smoothly, replace the bearings.
SC(H4SO)-18
Generator
3. STATOR
1) Continuity test Inspect continuity between the stator coil lead wire terminals. If the resistance is 1 M: or more, the lead wire is damaged. Replace the stator assembly.
(A)
4. BRUSH
1) Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush. Brush length: Service limit (1) 5.0 mm (0.197 in) Standard (2) 18.5 mm (0.728 in)
(1) (A)
SC-00047
(2)
(A) Stator
2) Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If the resistance is 1 : or less, the stator coil is grounded. Replace the stator assembly.
SC-00162
2) Check that there is appropriate pressure on the brush spring. Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of brush spring. If the pressure is 2.2 N (0.224 kgf, 7.91 oz) or less, replace the brush spring with a new one. 4.8 6.0 N (0.489 0.612 kgf, 17.26 21.58 oz) pressure is required on the new spring.
SC-00048
SC-00093
5. BEARING (FRONT SIDE)

Check the front ball bearing. Replace the ball bearings if there is resistance in the rotation, or if there is any abnormal noise.
SC(H4SO)-19
Battery
4. Battery
A: REMOVAL
1) Disconnect the positive (+) terminal after disconnecting the negative () terminal of battery. 2) Remove the harness clip of the negative terminal from the battery rod. 3) Remove the flange nut from battery rod and remove battery holder.
C: INSPECTION
WARNING: Electrolyte is corrosive acid, and has toxicity; be careful of handling the fluid. Make sure the electrode does not come into contact with skin, eyes or clothing. Especially at contact with eyes, flush with water for 15 minutes and get prompt medical attention. In addition, be careful not to let the electrode contact with the coated parts. Be careful when handling the batteries because they produce explosive gases. Be sure to keep battery away from any fire. For safety, in case an explosion does occur, wear eye protection or shield your eyes when working near any battery. In addition, never lean over the battery. Ventilate sufficiently when using or charging battery in enclosed space. Before starting work, remove rings, metal watch-bands, and other metal jewelry. Never allow metal tools to contact the positive battery terminal and anything connected to it while you are at the same time in contact with any other metallic portion of the vehicle.
SC-02238
4) Remove the battery.
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 3.5 Nm (0.4 kgf-m, 2.6 ft-lb) NOTE: Clean the battery cable terminals and apply grease to retard the formation of corrosion. Connect the battery positive (+) terminal, and then connect the negative () terminal. After the battery is installed, initial diagnosis of the electronic throttle control is performed. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.
1. EXTERNAL PARTS
Check the battery case, top cover, vent plugs, and terminal posts for dirt or cracks. If necessary, clean with water and wipe with a dry cloth. Apply a thin coat of grease on the terminal posts to prevent corrosion.
2. ELECTROLYTE LEVEL
Check the electrolyte level in each cell. If the level is below MIN level, bring the level to MAX level by pouring distilled water into the battery cell. Do not fill beyond MAX level.
SC(H4SO)-20
Battery
3. SPECIFIC GRAVITY OF ELECTROLYTE

1) Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20C (68F) using the following equation: S20= St + 0.0007 (t 20) S 20: Specific gravity corrected at electrolyte temperature of 20C (68F) St: Measured specific gravity t: Measured temperature (C) Determine whether or not battery must be charged, according to corrected specific gravity. Standard specific gravity: 1.220 1.290 [20C (68F)] 2) Measuring the specific gravity of the electrolyte in the battery will disclose the state of charge of the battery. The relation between specific gravity and state of charge is as shown in the figure.
Battery with standard specific gravity 1,280 (20 C)
1.28
D: MEASUREMENT
WARNING: Do not bring an open flame close to the battery when working. CAUTION: Prior to charging, corroded terminals should be cleaned with a brush and common caustic soda solution. Be careful since battery electrolyte overflows while charging the battery. Observe instructions when handling the battery charger. Before charging the battery on the vehicle, disconnect the battery ground terminal to prevent damage of generator diodes or other electrical units.
1. JUDGMENT OF BATTERY IN CHARGED CONDITION

1) Specific gravity of electrolyte should be held within the specific range from 1.250 to 1.290 for one hour or more. 2) Voltage per battery cell should be held at a specific value in a range from 2.5 to 2.8 V for one hour or more.
Specific gravity 20 ( C)
1.24 1.22 1.20 1.16 1.12 1.08 1.04 0 10 20 30 40 50 60 70 80 90
Need to charge
Good
2. CHECK CONDITION OF CHARGE WITH HYDROMETER

State of Corrective action charge 65% or more Load test 65% or less Charge battery Low Replace the battery.* Clear dot electrolyte (If cranking is difficult) * Check electrical system before replacement. Hydrometer indicator Green dot Dark dot
100
Amount of discharge (%)
SC-00054
3. NORMAL CHARGING
Charge the battery at the current value specified by manufacturer or at approximately 1/10 of batterys ampere-hour rating.
SC(H4SO)-21
Battery
4. QUICK CHARGING
Quick charging is a method that the battery is charged in a short period of time with a relatively large current by using a quick charger. Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time. For this reason, the quick charging must be carried out within a current range that will not increase the electrolyte temperature above 40C (104F). Also the quick charging is a temporary mean to bring battery voltage up to some level, and battery should be charged slowly with low current as a rule. CAUTION: Observe the items in 3. NORMAL CHARGING. Never use 10 A or more when charging the battery because it will shorten the battery life.
SC(H4SO)-22
Basic Diagnostic Procedure

ENGINE (DIAGNOSTICS)
1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE
1 Step Check CHECK ENGINE START FAILURE. Does the engine start? 1) Ask the customer when and how the trouble occurred using the interview checklist. <Ref. to EN(H4SO)(diag)-3, CHECK, Check List for Interview.> 2) Start the engine. Yes Go to step 2. No Inspection using Diagnostics for Engine Start Failure. <Ref. to EN(H4SO)(diag)64, Diagnostics for Engine Starting Failure.> Inspection using General Diagnostic Table <Ref. to EN(H4SO)(diag)300, INSPECTION, General Diagnostic Table.> Inspection using Diagnostics Procedure for Subaru Select Monitor Communication. <Ref. to EN(H4SO)(diag)78, Diagnostic Procedure for Subaru Select Monitor Communication.>
CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator Go to step 3. INDICATOR LIGHT. light illuminate?
CHECK THE COMMUNICATION STATUS. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor or general scan tool to the data link connector. 3) Turn the ignition switch to ON, and run the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed procedures, refer to Subaru Select Monitor. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK DTC. Read DTC using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR Refer to Read Diagnostic Trouble Code for detailed operation procedure. <Ref. to EN(H4SO)(diag)-40, Read Diagnostic Trouble Code (DTC).> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual.
Does Subaru select monitor or Go to step 4. general scan tool communicate with vehicle normally?
PERFORM DIAGNOSIS. 1) Perform the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> 2) Perform the Inspection Mode. <Ref. to EN(H4SO)(diag)-41, Inspection Mode.>
Repair the related parts. NOTE: If DTC is not shown on display although the malfunction indicator light illuminates, perform the diagnosis of malfunction indicator light circuit or combination meter. <Ref. to EN(H4SO)(diag)-55, Malfunction Indicator Light.> Finish the diagnoIs DTC displayed on the Subaru Inspect using Select Monitor or general scan Diagnostic Proce- sis. tool? dure with Diagnostic Trouble Code (DTC)<Ref. to EN(H4SO)(diag)87, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Is DTC displayed on the Subaru Record the DTC. Select Monitor or general scan Repair the trouble cause. <Ref. to tool? EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> Go to step 5.
EN(H4SO)(diag)-2
Check List for Interview

2. Check List for Interview

A: CHECK
1. CHECK LIST NO. 1
Check the following item when problem has occurred. NOTE: Use copies of this page for interviewing customers.
Customers name Date of purchase Date of repair V.I.N. Weather Engine No. Fuel brand Odometer reading Fine Cloudy Rainy Snowy Various/Others: C ( Hot Warm Cool Cold Highway Suburbs Inner city Uphill Downhill Rough road Others: Cold Warming-up After warming-up Any temperature Others: rpm km/h (MPH) Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning (RH/LH) ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF F) km miles
Ambient air temperature
Place
Engine temperature
Engine speed Vehicle speed Driving conditions
Headlight Blower A/C compressor Radiator fan Front wiper Rear wiper
Rear defogger Audio CD/Cassette Car phone Wireless device
ON/ ON/ ON/ ON/ ON/
OFF OFF OFF OFF OFF
EN(H4SO)(diag)-3

2. CHECK LIST NO. 2

Check the following item about the vehicles state when malfunction indicator light illuminates. NOTE: Use copies of this page for interviewing customers.
a) Other warning lights or indicators turn on. Yes / No Low fuel warning light Charge indicator light Engine coolant temperature indicator light Oil pressure warning light ATF temperature indicator light or SPORT indicator light Drivers control center differential indicator light ABS warning light VDC warning light Cruise indicator light SI-CRUISE warning light Immobilizer indicator light STEERING indicator light Glow indicator Sedimentor warning light Others: b) Fuel level Lack of gasoline: Yes / No Indicator position of fuel gauge: Experienced running out of fuel: Yes / No c) Intentional connecting or disconnecting of harness connectors or spark plug cords: What: d) Intentional connecting or disconnecting of hoses: Yes / No What: e) Installing of parts other than genuine parts: Yes / No What: Where: f) Occurrence of noise: Yes / No From where: What kind: g) Occurrence of smell: Yes / No From where: What kind: h) Intrusion of water into engine compartment or passenger compartment: i) Troubles occurred Engine does not start. Engine stalls during idling. Engine stalls while driving. Engine speed decreases. Engine speed does not decrease. Rough idling Poor acceleration Back fire After fire Does not shift. Excessive shift shock
Yes /
No
Yes /
No
EN(H4SO)(diag)-4
General Description
A: CAUTION
1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay. CAUTION: Do not use the electrical test equipment on airbag system circuits. Be careful not to damage the airbag system wiring harness when servicing the ECM, TCM, main relay and fuel pump relay. 2) Never connect the battery in reverse polarity. Failure to do so will damage the ECM instantly, and other parts will also be damaged. 3) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as ECM etc. 4) Before disconnecting the connectors of each sensor and ECM, be sure to turn the ignition switch to OFF. Perform the Clear Memory Mode after connecting the connectors. <Ref. to EN(H4SO)(diag)50, Clear Memory Mode.> 5) When measuring the voltage or resistance of individual sensor or all electrical control modules, use a tapered pin with a diameter of less than 0.6 mm (0.024 in). Do not insert the pin 4 mm (0.16 in) or more into the part. CAUTION: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system. NOTE: When replacing the ECM of the models with Immobilizer, immobilizer system must be registered. To do so, all ignition keys and ID cards need to be prepared. Refer to the PC application help for Subaru Select Monitor. 6) Take care not to allow water to get into the connector when servicing the vehicle in rainy weather or when washing the vehicle. Avoid exposure to water even if the connectors are waterproof.
7) Use ECM mounting stud bolts at the body side grounding point when measuring voltage and resistance inside the passenger compartment.
(A)
EN-00001
(A) Stud bolt
8) Use the engine ground terminal or engine assembly for the grounding point to chassis when measuring the voltage and resistance in engine compartment.
FU-01090
9) Every engine control system-related part is a precision part. Do not drop them. 10) Observe the following cautions when installing a radio in vehicle. CAUTION: The antenna must be kept as far apart as possible from control module. (ECM is installed under the passenger's side floor mat.) The antenna feeder must be placed as far apart as possible from the ECM and engine control system harness. Carefully adjust the antenna for correct matching. When mounting a large power type radio, pay special attention to the three items mentioned above. Incorrect installation of the radio may affect the operation of ECM. 11) When disconnecting the fuel hose, release the fuel pressure. <Ref. to FU(H4SO)-43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
EN(H4SO)(diag)-5
General Description
12) For the model with ABS, the ABS warning light may illuminate when performing driving test with jacked-up or lifted-up condition, but this is not a system malfunction. The reason for this is the speed difference between the front and rear wheels. After diagnosis of engine control system, perform the ABS memory clear procedure of selfdiagnosis function.
C: NOTE
The on-board diagnostic (OBD) system detects and indicates a fault in various inputs and outputs of the complex electronic control. Malfunction indicator light in the combination meter indicates occurrence of a fault or trouble. Further, against such a failure or sensors as may disable the drive, the fail-safe function is provided to ensure the minimal drivability. The OBD system incorporated with the vehicles within this type of engine complies with OBD-II regulations. The OBD system monitors the components and the system malfunction listed in Engine Section which affects on emissions. When the system decides that a malfunction occurs, malfunction indicator light illuminates. At the same time of the malfunction indicator light illumination or blinking, a DTC and a freeze frame engine conditions are stored into on-board computer. The OBD system stores freeze frame engine condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle speed, etc.) into on-board computer when it detects a malfunction. Freeze frame engine condition data are stored until the DTCs are cleared. However when such malfunctions as fuel trim fault and misfire are detected with the freeze frame engine condition data stored, they are rewritten into those related to the fuel trim fault and misfire. When the malfunction does not occur again for three consecutive driving cycles, malfunction indicator light is turned off, but DTC remains at onboard computer. When troubleshooting the vehicle which complies with OBD-II regulations, connect the Subaru Select Monitor or general scan tool to the vehicle.
B: INSPECTION
Before performing diagnostics, check the following item which might affect engine problems.
1. BATTERY
1) Measure the battery voltage and specific gravity of the electrolyte. Standard voltage: 12 V Specific gravity: 1.260 or more 2) Check the condition of the main and other fuses, and harnesses and connectors. Also check for proper grounding.
2. ENGINE GROUND
Check if the engine ground terminal is properly connected to engine.
FU-01090
EN(H4SO)(diag)-6
General Description
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER 1B022XU0 DESCRIPTION SUBARU SELECT MONITOR III KIT REMARKS Used for troubleshooting the electrical system.
ST1B022XU0
499987500
CRANKSHAFT SOCKET
ST-499987500
EN(H4SO)(diag)-7
Electrical Component Location

4. Electrical Component Location

A: LOCATION
1. CONTROL MODULE
(3) (1)
(4)
(2)
EN-05727
(1) (2)
Engine control module (ECM) Malfunction indicator light
(3)
Delivery (test) mode connector
(4)
Data link connector
(1)
CHECK ENGINE
EN-01147
(2)
EN-05735
(4) (3)
EN-02975
AT-01877
EN(H4SO)(diag)-8

2. SENSOR
(1)
(8)
(3)
(4)
(2)
(7)
(5)
(6)
EN-05728
(1) (2)
Mass air flow and intake air temperature sensor Manifold absolute pressure sensor
(3) (4) (5)
Engine coolant temperature sensor Electronic throttle control Knock sensor
(6) (7) (8)
Camshaft position sensor Crankshaft position sensor Oil temperature sensor
EN(H4SO)(diag)-9

(2) (1) EN-05729 EN-01971
(3)
(4) EN-02179 EN-01972
(5) (6) EN-00010 (7) EN-00011
EN-00012
(8)
EN-04089
EN(H4SO)(diag)-10

(4)
(3)
(2)
(1)
EN-03847
(1) (2)
Front oxygen (A/F) sensor Rear oxygen sensor
(3)
Front catalytic converter
(4)
Rear catalytic converter
EN(H4SO)(diag)-11

(1) (2)
(3)
(4) EN-05730
(1) (2)
Fuel level sensor Fuel temperature sensor
(3)
Fuel tank pressure sensor
(4)
Fuel sub level sensor
(3)
(1)
(2) EN-05725 EN-03003
(4)
EN-03132
EN(H4SO)(diag)-12

3. SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS
(5) (6)
(4)
(3)
(2)
(4)
(1)
(6) (5)
EN-05731
(1) (2) (3)
Purge control solenoid valve EGR valve Ignition coil and ignitor ASSY
(4) (5)
Fuel injector Oil switching solenoid valve
(6)
Variable valve lift diagnosis oil pressure switch
EN(H4SO)(diag)-13

(1)
(2)
EN-05732
EN-01976
(3)
EN-03105
(4)
EN-03106
(6) (5) EN-04985
EN(H4SO)(diag)-14

(1)
(2)
(3)
(4)
EN-05733
(1) (2)
Pressure control solenoid valve Canister
(3)
Drain valve
(4)
Drain filter
(4) (3)
(2) (1) EN-02980 EN-02981
EN(H4SO)(diag)-15

(5) (4) (3) (2)
(1)
(8)
(7)
(6)
(9)
EN-05734
(1) (2) (3)
Inhibitor switch Fuel pump Main relay
(4) (5) (6)
Fuel pump relay Electronic throttle control relay Radiator main fan relay 1
(7) (8) (9)
Radiator sub fan relay Radiator main fan relay 2 Starter
(1) (2)
EN-06888
EN-05726
(4)
(8) (3) (5) (6) EN-03150 EN-06796 (7)
(9)
EN-02096
EN(H4SO)(diag)-16
Engine Control Module (ECM) I/O Signal

5. Engine Control Module (ECM) I/O Signal

A: ELECTRICAL SPECIFICATION
TO A:
B134 2 1 10 9 8 20 19 18 30 29 28
TO B:
B135
TO C:
B136
TO D:
B137
7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31
7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28
6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 17 30 29 28 35 34 33 32 31
7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26
EN-05288
Contents Signal (+) Signal () Shield Signal (+) Signal () Shield Main Electronic throtSub tle control Power supply GND (sensor) Electronic throttle control motor (+) Electronic throttle control motor () Electronic throttle control motor power supply Electronic throttle control motor relay
Connector No. B134 B134 B134 B134 B134 B134 B134
Terminal No. 13 14 24 12 22 24 18
Crankshaft position sensor Camshaft position sensor
Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 7 +7 0 0 0 0 0 7 +7 0 0 0 0 0.64 0.72 Fully opened: 3.96 1.51 1.58 Fully opened: 4.17 5 0 Duty waveform Duty waveform 10 13 ON: 0 OFF: 10 13 0.64 0.72 (After engine is warmed up.) 1.51 1.58 (After engine is warmed up.) 5 0 Duty waveform Duty waveform 12 14 ON: 0 OFF: 12 14
Note Waveform Waveform Fully closed: 0.6 Fully opened: 3.96 Fully closed: 1.48 Fully opened: 4.17 Drive frequency: 500 Hz Drive frequency: 500 Hz When ignition switch is turned to ON: ON
B134 B134 B134 B137 B137 B136 B136
28 19 29 5 4 1 21
EN(H4SO)(diag)-17

Connector No. B135 B135 B135 B135 B135 B135 B135 B135 B136 B136 B136 B134 Terminal No. 23 21 29 31 22 30 4 1 3 2 4 34 Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) Fully closed: 1.0 Fully closed: 1.0 Fully opened: 3.5 Fully opened: 3.5 5 0 Fully closed: 1.0 Fully opened: 3.5 5 0 0 0 10 13 10 13 10 13 1.0 1.4 5 0 Fully closed: 1.0 Fully opened: 3.5 5 0 0 0.9 0 1 14 1 14 1 14 1.0 1.4
Contents Main sensor signal Main power supply GND (Main sensor) Sub sensor signal Sub power supply GND (Sub sensor) Signal Shield Signal 1
Note
Duty waveform Duty waveform Duty waveform After engine is warmed up. AT model Cranking: 8 14 MT model Cranking with the clutch pedal pressed: 8 14 AT model: Switch is ON when select lever is shifted into P range or N range. MT model: Switch is ON when the shift lever is in neutral. When connected: 0 Ignition switch OFF: 10 13 Waveform Waveform Waveform Waveform Waveform Waveform
Accelerator pedal position sensor
Rear oxygen sensor
Front oxygen (A/F) sensor Signal 2 heater Rear oxygen sensor heater signal Engine coolant temperature sensor
Starter switch
B136
32
Starter relay control A/C switch Ignition switch
B136 B136 B135
20 24 19
ON: 0.5 or less OFF: 10 13 ON: 10 13 OFF: 0 10 13
ON: 0.5 or less OFF: 12 14 ON: 12 14 OFF: 0 12 14
Neutral position switch
B136
31
ON: 0 OFF: 12r0.5
Delivery (test) mode connector Signal Knock sensor Shield Back-up power supply Control module power supply Ignition control #1, #2 #3, #4 #1 #2 #3 #4
B135 B134 B134 B135 B134 B135 B137 B137 B137 B137 B137 B137
27 15 25 5 7 2 18 19 8 9 10 11
10 13 2.5 0 10 13 10 13 10 13 0 0 10 13 10 13 10 13 10 13
13 14 2.5 0 12 14 12 14 12 14 1 3.4 1 3.4 1 14 1 14 1 14 1 14
Fuel injector
EN(H4SO)(diag)-18

Connector No. B136 B136 B136 B136 B136 B136 B136 B134 B134 B137 B134 B134 B134 B134 B134 B135 B136 B137 B137 B137 B137 B134 B134 B135 B135 B135 B134 B135 B135 B135 B135 B136 B136 Terminal No. 12 9 18 29 23 11 22 23 30 29 8 9 10 20 33 11 33 25 24 31 30 31 32 9 8 1 6 26 35 34 18 26 34 Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) ON: 0.5 or less ON: 0.5 or less OFF: 10 13 OFF: 12 14 ON: 0.5 or less ON: 0.5 or less OFF: 10 13 OFF: 12 14 ON: 0.5 or less ON: 0.5 or less OFF: 10 13 OFF: 12 14 ON: 0.5 or less OFF: 10 13 0.5 or less 1.0 1.4 0 ON: 1 or less OFF: 10 13 0 or 10 13 0 or 10 13 0 or 10 13 0 or 10 13 ON: 1 or less OFF: 10 13 ON: 0 OFF: 10 13 ON: 0 OFF: 10 13 0 0 0 0 0 0 0 3.4 3.8 0 0 0.3 4.6 1 or less mo 4 or more 1 or less mo 4 or more ON: 0.5 or less OFF: 12 14 0.5 or less 0 13 or more 1.0 1.4 0 ON: 1 or less OFF: 12 14 0 or 12 14 0 or 12 14 0 or 12 14 0 or 12 14 ON: 1 or less OFF: 12 14 ON: 0 OFF: 12 14 ON: 0 OFF: 12 14 Duty waveform 0 Duty waveform 0 0 0 2.7 2.9 2.35 2.25 0 1.4 1.8 0.3 4.5 0 0 0.3 4.6 1 or less mo 4 or more 1 or less mo 4 or more
Contents
Note
Fuel pump relay control A/C relay control Radiator fan relay 1 control Radiator fan relay 2 control Self-shutoff control Malfunction indicator light Engine speed output Oil temperature sensor signal PCV diagnosis connector Purge control solenoid valve Signal 1 Signal 2 Signal 3 Signal 4
Light ON: 1 or less Light OFF: 10 14 Waveform After engine is warmed up. Duty waveform Waveform Waveform Waveform Waveform Drive frequency: 300 Hz Drive frequency: 300 Hz
EGR valve
Power steering oil pressure switch Blower fan switch A/C middle pressure switch Oil switching solenoid valve RH Oil switching solenoid valve LH Signal (+) Signal () Signal (+)
Signal () Variable valve lift diagnosis oil pressure switch RH Variable valve lift diagnosis oil pressure switch LH Signal (+) Signal () Shield Manifold absolute pressure sensor Signal Air flow sensor Shield Ground Intake air temperature sensor signal Front oxygen (A/F) sensor Immobilizer communication 1 Immobilizer communication 2
EN(H4SO)(diag)-19

Connector No. B136 B134 B135 B134 B135 B134 B137 B137 B137 B137 B137 B137 B136 B136 Terminal No. 16 19 22 29 30 5 7 2 1 3 26 6 6 25 Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 1 or less mo 4 or 1 or less mo 4 or more more 5 5 5 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 When clutch pedal is When clutch pedal is depressed: 0 depressed: 0 When clutch pedal is When clutch pedal is released: 10 13 released: 12 14 When brake pedal is depressed: 0 When brake pedal is released: 10 13 When brake pedal is depressed: 10 13 When brake pedal is released: 0 When brake pedal is depressed: 0 When brake pedal is released: 12 14 When brake pedal is depressed: 12 14 When brake pedal is released: 0
Contents
Note
SSM communication line Sensor power supply GND (sensor) (Engine 1) (Engine 2) (Engine 3) (Engine 4) (Engine 5) (Ignition 1) (Ignition 2) (Body)
Ground
Clutch switch
Brake switch 1
B135
20
Brake switch 2
B135
28
Cruise control main switch
B135
12
Cruise control command switch
B135
24
ON: 0 ON: 0 OFF: 5 OFF: 5 When not operating: When not operating: 3.5 4.5 3.5 4.5 When operating When operating RES/ACC: 2.5 3.5 RES/ACC: 2.5 3.5 When operating SET/ When operating SET/ COAST: 0.5 1.5 COAST: 0.5 1.5 When operating When operating CANCEL: 0 0.5 CANCEL: 0 0.5 2.5 3.8 2.3 2.7 ON: 1 or less OFF: 10 13 ON: 1 or less OFF: 10 13 2.5 3.5 1.5 2.5 2.5 3.8 2.3 2.7 ON: 1 or less OFF: 12 14 ON: 1 or less OFF: 12 14 2.5 3.5 1.5 2.5
Fuel temperature sensor Fuel tank pressure sensor Pressure control solenoid valve Drain valve CAN communication line (+) CAN communication line () AT/MT identification line
B135 B135 B136 B136 B136 B136 B136
17 32 28 17 27 35 15
Ambient temperature: 25C (77F) Value after removing fuel filler cap and installing again Waveform Waveform MT model: 1 or less
EN(H4SO)(diag)-20

Input/output name 1. Crankshaft position sensor Measuring condition At idling Waveform
10ms 5V
ONE CRANK ROTATION
EN-05322
2. Camshaft position sensor
At idling
50ms 5V
ONE CAM ROTATION
EN-05323
EN(H4SO)(diag)-21

F/B FUSE No. 4 DATA LINK CONNECTOR MT C25 IGNITION SWITCH F/B FUSE No. 21 STARTER RELAY CLUTCH START SWITCH C20 C16 MT CLUTCH SWITCH MT MT B27 C32 DELIVERY (TEST) MODE CONNECTOR AT M/B FUSE No. 13 F/B FUSE No. 12 M/B FUSE No. 11 MT NEUTRAL POSITION SWITCH MT ACCELERATOR PEDAL POSITION SENSOR FUEL TANK PRESSURE SENSOR JOINT CONNECTOR B30 FUEL PUMP RELAY B5 B19 C6
STARTER MOTOR
JOINT CONNECTOR
1
B23
MT
INHIBITOR SWITCH
AT
C31
B21 B31
C12 SD FUEL PUMP CONDENSER
B29
B22 FUEL PUMP SD
POWER STEERING OIL PRESSURE SWITCH A33 B32
14 9
SD : SEDAN MODEL
EN-06829
EN(H4SO)(diag)-22

SBF No. 7 SBF No. 5
MAIN RELAY
A/F & OXYGEN SENSOR RELAY
RELAY HOLDER
ELECTRONIC THROTTLE CONTROL RELAY
D18
4
C1 C21 D26 D19 IGNITION COIL & IGNITOR ASSY
D6 C23
A7 B2 F/B FUSE No.7
F/B FUSE No.5 PURGE CONTROL SOLENOID VALVE D29
COMBINATION METER C11 BODY INTEGRATED UNIT (CAN COMMUNICATION) MALFUNCTION INDICATOR LIGHT
A8
CAN TRANSCEIVER & RECEIVER
I/F
POWER SUPPLY CIRCUIT
MICRO COMPUTER
A9
C22
TACHOMETER
I/F
EGR VALVE
ABS
I/F
SPEEDOMETER
A10 ABS CONTROL MODULE

ENGINE COOLANT TEMPERATURE GAUGE
5
A20
JOINT GROUND CONNECTOR
EN-05694
EN(H4SO)(diag)-23

FUEL INJECTOR No. 1
D8
A18
FUEL INJECTOR No. 2
D9
6
A28 ELECTRONIC THROTTLE CONTROL
D4 FUEL INJECTOR No. 3 D10 D5 A19
FUEL INJECTOR No. 4
D11
A6 C17 A29
DRAIN VALVE
MANIFOLD ABSOLUTE PRESSURE SENSOR
A34 ENGINE COOLANT TEMPERATURE SENSOR
PRESSURE CONTROL SOLENOID VALVE
C28
10
OIL TEMPERATURE SENSOR
A23
14 5
B17 FUEL TEMPERATURE SENSOR
EN-05036
EN(H4SO)(diag)-24

B18
MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR
B34 A32 VVL DIAGNOSIS OIL PRESSURE SWITCH LH
B26 A31 B35
VVL DIAGNOSIS OIL PRESSURE SWITCH RH
D30 D31 OIL SWITCHING SOLENOID VALVE LH
B9 FRONT OXYGEN (A/F) SENSOR RH B8 C2
D24 D25 OIL SWITCHING SOLENOID VALVE RH
2 10
REAR OXYGEN SENSOR LH
C3 B1 C4
A13 A14 CRANKSHAFT POSITION SENSOR
12
B4 A12
11
A22 A24
CAMSHAFT POSITION SENSOR
13 7
A15 KNOCK SENSOR
A25
EN-05695
EN(H4SO)(diag)-25

STOP LIGHT SWITCH
B28 C24 AUTO A/C CONTROL MODULE
BRAKE SWITCH
B20
C33
A/C PRESSURE SWITCH
C9 B12
A/C RELAY
CRUISE CONTROL SWITCH B24
C26 BODY INTEGRATED UNIT (IMMOBILIZER) C34
B11
BLOWER FAN RELAY
2 11
C27 BODY INTEGRATED UNIT (CAN COMMUNICATION) C35 D7 D3 SUB FAN RELAY C18 D2 D1
6 12 13 8
C15
MT
MAIN FAN RELAY
C29
A5
ENGINE GROUND
EN-05696
EN(H4SO)(diag)-26
Engine Condition Data

6. Engine Condition Data

Contents Engine Load Specification 17.6 40.5 (%): Idling 14.7 29.8 (%): 2,500 rpm racing
Measuring condition: After engine is warmed up. Set the select lever in P range or N range, or the shift lever in neutral. Turn the A/C off. Turn all the accessory switches to OFF.
EN(H4SO)(diag)-27
Data Link Connector

7. Data Link Connector

A: NOTE
This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools except Subaru Select Monitor or general scan tool because the circuit for Subaru Select Monitor may be damaged.
9 10 11 12 13 14 15 16
EN-04893
Terminal No. 1 2 3 4 5 6 7 8
Contents Blank Blank Blank Ground Ground CAN (+) Subaru Select Monitor signal Blank
Terminal No. 9 10 11 12 13 14 15 16
Contents Blank Blank Blank Blank Blank CAN () Blank Power supply
EN(H4SO)(diag)-28
General Scan Tool

8. General Scan Tool

A: OPERATION
1. HOW TO USE GENERAL SCAN TOOL
1) Prepare a scan tool (general scan tool) required by SAE J1978. 2) Open the cover and connect the general scan tool to the data link connector located in the lower area of instrument panel (on the drivers side).
EN-02533
3) Using the general scan tool, call up DTC and freeze frame data. General scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain DTC (4) MODE $04: Clear/Reset emission-related diagnostic information (5) MODE $06: Request on-board monitoring test results for intermittently monitored systems (6) MODE $07: Request on-board monitoring test results for continuously monitored systems (7) MODE $09: Request vehicle information Read out the data according to repair procedures. (For detailed operation procedure, refer to the general scan tool operation manual.) NOTE: For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)-80, List of Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-29
General Scan Tool

2. MODE $01: (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refer to data denoting the current operating condition of analog input/output, digital input/output or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID $01 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $13 $15 $1C $1F $21 $24 $2C $2D $2E $2F $30 $31 $32 $33 $34 $3C $41 $42 $43 $44 $45 $46 $47 $49 $4A $4C $4D $4E $51 $5A Data Unit of measure Number of emission-related powertrain DTC, and malfunction indicator light status and diagnosis support information Fuel system control status Calculated engine load value % Engine coolant temperature C Short term fuel trim % Long term fuel trim % Intake manifold absolute pressure kPa Engine speed rpm Vehicle speed MPH Ignition timing advance Intake air temperature C Air flow rate from the mass air flow sensor g/s Throttle valve absolute opening angle % Check whether oxygen sensor is installed. Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 1 Sensor 2) V and % Supporting OBD system Elapsed time after starting the engine sec Travel distance after the malfunction indicator light illuminates miles A/F value and A/F sensor output voltage (Bank 1 Sensor 1) and V Target EGR % EGR deviation % Evaporative purge % Fuel level % Number of warm ups after DTC clear Travel distance after DTC clear miles Fuel tank pressure Pa Atmospheric pressure kPa A/F value and A/F sensor current (Bank 1 Sensor 1) and mA Catalyst temperature #1 C Diagnosis monitoring per drive cycle ECM power supply voltage V Absolute load % A/F target lambda Relative throttle opening angle % Ambient temperature C Absolute throttle opening angle 2 % Absolute accelerator opening angle 1 % Absolute accelerator opening angle 2 % Target throttle opening angle % Engine operating time while malfunction indicator lit min Elapsed time after DTC clear min Fuel used Relative acceleration opening angle %
NOTE: Refer to general scan tool manufacturers instruction manual to access generic OBD-II PIDs (MODE $01).
EN(H4SO)(diag)-30
General Scan Tool

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refer to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID $02 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $13 $15 $1C $1F $2C $2D $2E $2F $32 $33 $42 $43 $44 $45 $46 $47 $49 $4A $4C Data Unit of measure DTC that caused the freeze frame data storage required by CARB Fuel system control status Calculated engine load value % Engine coolant temperature C Short term fuel trim (Bank 1 Sensor 1) % Long term fuel trim (Bank 1 Sensor 1) % Intake manifold absolute pressure kPa Engine speed rpm Vehicle speed MPH Ignition timing advance Intake air temperature C Air flow rate from the mass air flow sensor g/s Throttle valve absolute opening angle % Check whether oxygen sensor is installed. Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 1 Sensor 2) V and % Supporting OBD system Elapsed time after starting the engine sec Target EGR % EGR deviation % Evaporative purge % Fuel level % Fuel tank pressure Pa Atmospheric pressure kPa ECM power supply voltage V Absolute load % A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle % C % % % %
NOTE: Refer to general scan tool manufacturers instruction manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC)

Refer to List of Diagnostic Trouble Code (DTC) for information about data denoting emission-related powertrain DTC. <Ref. to EN(H4SO)(diag)-80, List of Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)

Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic information). NOTE: Refer to general scan tool manufacturers instruction manual to clear the emission-related diagnostic information (MODE $04).
EN(H4SO)(diag)-31
General Scan Tool

6. MODE $06
Refer to test value of troubleshooting and data of test limit indicated on the support data bit sequence table. A list of the support data is shown in the following table.
OBDMID TID $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $89 $8A $93 $94 $95 $96 $97 $98 $99 $9A $9B $9C $9D $0B $0C $0B $0C $0B $0C $0B $0C $0B $0C SID $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $20 $FD $FE $FE $FE $FE $FE $FE $24 $24 $14 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 Diagnostic item A/F sensor continuity abnormal (Bank 1 Sensor 1)
$01
A/F sensor range abnormal (Bank 1 Sensor 1) A/F sensor response abnormal (Bank 1 Sensor 1) Oxygen sensor circuit abnormal (Bank 1 Sensor 2)
$02
Oxygen sensor drop abnormal (Bank 1 Sensor 2)
Oxygen sensor response abnormal (Bank 1 Sensor 2) Catalyst deterioration diagnosis (Bank 1) EGR system diagnosis Evaporative emission control system (Cap off) Evaporative emission control system (0.04 inch leak) Evaporative emission control system (0.02 inch leak) Evaporative emission control system (Purge flow) A/F sensor heater abnormal (Bank 1 Sensor 1) A/F sensor heater characteristics abnormal (Bank 1 Sensor 1) Oxygen sensor heater abnormal (Bank 1 Sensor 1) Misfire monitoring (All cylinders) Misfire monitoring (#1 cylinder) Misfire monitoring (#2 cylinder) Misfire monitoring (#3 cylinder) Misfire monitoring (#4 cylinder)
$21 $31 $39 $3B $3C $3D $41
$42 $A1 $A2 $A3 $A4 $A5
7. MODE $07
Refer to the data of DTC (pending code) for troubleshooting result about emission in the first time.
8. MODE $09
Refer to data of vehicle specification (V.I.N., calibration ID, diagnosis frequency etc.).
EN(H4SO)(diag)-32
Subaru Select Monitor

9. Subaru Select Monitor

A: OPERATION
1. HOW TO USE THE SUBARU SELECT MONITOR
1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO)(diag)-7, PREPARATION TOOL, General Description.>
EN-05692
2) Prepare PC with Subaru Select Monitor installed. 3) Connect the USB cable between SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 4) Connect the diagnosis cable to SDI. 5) Connect SDI to data link connector located in the lower portion of the instrument panel (on the drivers side).
EN-02533
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 8) Call up DTC and data, then record them. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4SO)(diag)-33

2. READ CURRENT DATA FOR ENGINE (NORMAL MODE)

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {Current Data Display & Save}. 5) On the Current Data Display & Save display screen, select the {Normal sampling}. 6) Using the scroll key, scroll the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Engine load Engine coolant temperature signal A/F correction 1 A/F learning 1 Intake manifold absolute pressure Display Engine Load Coolant Temp. A/F Correction #1 A/F Learning #1 Mani. Absolute Pressure Unit of measure % C or F % % mmHg, kPa, inHg or psig rpm km/h or MPH deg C or F g/s or lb/m % V V V ms mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig deg % C or F % STEP mA : % % % V V V V V km/h or MPH : Note (at idling) 21.0% 85C or 185F or more (after warm up) 0.8% 0.0% 200 300 mmHg, 26.7 40 kPa, 7.8 11.8 inHg or 3.8 5.8 psig 700 rpm (Agree with the tachometer indication) 0 km/h or 0 MPH (at parking) 14 16 deg (Ambient air temperature) 2.5 g/s or 0.33 lb/m 2.0% 0.1 0.7 V 12 14 V 1.26 V 2.82 ms (Atmospheric pressure) (Air intake absolute pressure Atmospheric pressure) 0 deg 0.0% +20C or +68F 0 3% 0 STEP 0.2 0.2 mA 32 : 1.0 0.3% 0.00% 15% (Battery voltage) 1.52 V 0.66 V 0.68 V 0.68 V 0 km/h or 0 MPH 2 96 :
Engine speed signal Meter vehicle speed signal Ignition timing signal Intake air temperature signal Intake air amount Throttle opening angle signal Rear oxygen sensor voltage Battery voltage Mass air flow voltage Injection 1 pulse width Atmospheric pressure signal Intake manifold relative pressure Ignition timing learning value Acceleration opening angle signal Fuel temperature signal Purge control solenoid duty ratio Number of EGR steps A/F sensor current value 1 A/F sensor resistance value 1 A/F Sensor # 1 A/F correction 3 A/F learning 3 Throttle motor duty Throttle power supply voltage Sub throttle sensor voltage Main throttle sensor voltage Sub accelerator sensor voltage Main acceleration sensor voltage Memory vehicle speed Fuel level sensor signal
Engine Speed Vehicle Speed Ignition Timing Intake Air Temp. Mass Air Flow Throttle Opening Angle Rear O2 Sensor Battery Voltage Air Flow Sensor Voltage Fuel Injection #1 Pulse Atmosphere Pressure Mani. Relative Pressure Learned Ignition Timing Accel. Opening Angle Fuel Temp. CPC Valve Duty Ratio No. of EGR steps A/F Sensor #1 Current A/F Sensor #1 Resistance A/F Sensor #1 A/F Correction #3 A/F Learning #3 Throttle Motor Duty Throttle Motor Voltage Sub-Throttle Sensor Main-Throttle Sensor Sub-Accelerator Sensor Main-Accelerator Sensor Memorized Cruise Speed Fuel level resistance
EN(H4SO)(diag)-34

Contents Engine oil temperature Oil switching solenoid valve duty R Oil switching solenoid valve duty L Oil switching solenoid valve current R Oil switching solenoid valve current L Variable valve lift mode #1 cylinder roughness monitor #2 cylinder roughness monitor #3 cylinder roughness monitor #4 cylinder roughness monitor Knock sensor correction Fuel tank pressure signal AT/MT identification terminal Delivery (test) mode terminal D check request flag Delivery (test) mode terminal Neutral position switch signal Soft idle switch signal Ignition switch signal Power steering switch signal Air conditioning switch signal Starter switch signal Rear oxygen monitor Knocking signal Crankshaft position sensor signal Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Light switch signal A/C middle pressure switch signal Air conditioner compressor relay output signal Radiator fan relay 1 signal Radiator fan relay 2 signal Fuel pump relay signal PCV hose assembly diagnosis signal Pressure control solenoid valve signal Drain valve signal Variable valve lift diagnosis oil pressure switch signal 1 Variable valve lift diagnosis oil pressure switch signal 2 AT coordinate retard angle demand signal AT coordinate fuel cut demand signal Torque control permission signal Electronic throttle control motor relay signal Clutch switch signal Stop light switch signal SET/COAST switch signal Display Oil Temperature OSV Duty R OSV Duty L OSV Current R OSV Current L VVL Lift Mode Roughness Monitor #1 Roughness Monitor #2 Roughness Monitor #3 Roughness Monitor #4 Knocking Correction Fuel Tank Pressure AT Vehicle ID Signal Test Mode Signal D-check Require Flag Delivery Mode Connector (Test Mode Connector) Neutral Position Switch Idle Switch Signal Ignition Switch P/S Switch Signal A/C Switch Starter Switch Rear O2 Rich Signal Knocking Signal Crankshaft Position Sig. Camshaft Position Sig. Rear Defogger SW Blower Fan SW Light Switch A/C Mid Pressure Switch A/C Compressor Signal Radiator Fan Relay #1 Radiator Fan Relay #2 Fuel Pump Relay Blow-by leak Connector PCV Solenoid Valve Vent. Solenoid Valve Eng. Oil Press. SW 1 Eng. Oil Press. SW 2 Retard Signal from AT Fuel Cut signal from AT Torque Permission Signal ETC Motor Relay Clutch Switch Stop Light Switch SET/COAST SW Unit of measure C % % mA mA deg mmHg, kPa, inHg or psig Note (at idling) t 85C (After engine is warmed up.) 16.9% 16.9% 192 mA 192 mA 1 0 0 0 0 0.0 deg +7.7 mmHg, +1.1 kPa, +0.31 inHg or +0.15 psig AT vehicle/MT vehicle OFF OFF OFF ON ON ON OFF input (When OFF) OFF input (When OFF) OFF Rich/Lean None ON ON OFF input (When OFF) OFF input (When OFF) OFF input (When OFF) OFF input (When OFF) OFF output (when OFF) OFF output (when OFF) OFF output (when OFF) ON output Connected OFF output OFF output ON ON None None Allowed (prohibited on MT vehicles) ON OFF (when OFF) OFF (when OFF) OFF (when OFF)
EN(H4SO)(diag)-35

Contents RES/ACC switch signal Brake switch signal Main switch signal Body integrated unit data reception Body integrated unit counter update Cruise control cancel switch signal Malfunction indicator light signal Display RESUME/ACCEL SW Brake Switch Main Switch Body Int. Unit Data Body Int. Unit Count CC Cancel SW MIL On Flag Unit of measure Note (at idling) OFF (when OFF) OFF input (When OFF) OFF input (When OFF) ON ON OFF input (When OFF) Off (when unlit)
NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
3. READ CURRENT DATA FOR ENGINE (OBD MODE)

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Current Data Display & Save}. 6) On the Current Data Display & Save display screen, select the {All Data Display}. 7) Using the scroll key, scroll the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Number of diagnosis code Condition of malfunction indicator light Monitoring test of misfire Monitoring test of misfire Monitoring test of fuel system Monitoring test of fuel system Monitoring test of comprehensive component Monitoring test of comprehensive component Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system Test of evaporative emission purge control system Secondary air system test Secondary air system test Test of air conditioning system refrigerant Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Display Number of Diag. Code: MI (MIL) Misfire monitoring (Supp) Misfire monitoring (Rdy) Fuel system monitoring (Supp) Fuel system monitoring (Rdy) Component monitoring (Supp) Component monitoring (Rdy) Catalyst Diagnosis (Supp) Catalyst Diagnosis (Rdy) Heated catalyst (Supp) Heated catalyst (Rdy) Evaporative purge system (Supp) Evaporative purge system (Rdy) Secondary air system (Supp) Secondary air system (Rdy) A/C system refrigerant (Supp) A/C system refrigerant (Rdy) Oxygen sensor (Supp) Oxygen sensor (Rdy) Referential value (at idling) 0 OFF YES YES YES YES YES YES YES NO NO N/A YES NO NO N/A NO N/A YES NO Unit of measure
EN(H4SO)(diag)-36

Contents Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal #1 Cylinder ignition timing Intake air temperature signal Intake air amount Throttle position signal Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (bank 1 sensor 1) Oxygen sensor (Bank 1 Sensor 2) Elapsed time after engine start Travel distance after the malfunction indicator light illuminates A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) Target EGR EGR error Evaporative purge Fuel level signal Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure signal Atmospheric pressure signal A/F lambda signal (Bank 1 Sensor 1) A/F sensor current (Bank 1 Sensor 1) Catalytic temperature#1 Monitoring test of misfire Monitoring test of misfire Monitoring test of fuel system Monitoring test of fuel system Monitoring test of comprehensive component Monitoring test of comprehensive component Display O2 Heater Diagnosis (Supp) O2 Heater Diagnosis (Rdy) EGR system (Supp) EGR system (Rdy) Fuel system for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start Lighted MI lamp history A/F Sensor #11 A/F Sensor #11 Commanded EGR EGR Error Commanded Evap Purge Fuel Level Number of warm-ups Meter since DTC cleared Fuel Tank Pressure Atmosphere Pressure A/F Sensor #11 A/F Sensor #11 Catalyst Temperature #11 Misfire monitoring (Enable) Misfire monitoring (Comp) Fuel system monitoring (Enable) Fuel system monitoring (Comp) Component monitoring (Enable) Component monitoring (Comp) Referential value (at idling) YES NO YES NO Cl_normal 23.0 92 0.8 0.0 211 700 0 16.0 36 2.7 13 0.7 0.0 OBD/OBD2 Support Support 1.001 2.79 0 8.8 Atmospheric pressure 1.001 0.00 YES NO YES NO YES NO Unit of measure % C % % mmHg rpm km/h C g/s % V % sec km V % % % % km mmHg mmHg mA C
EN(H4SO)(diag)-37

Contents Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system Test of evaporative emission purge control system Secondary air system test Secondary air system test Test of air conditioning system refrigerant Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light lit Elapsed time after DTC clear Fuel used Relative acceleration opening angle Display Catalyst Diagnosis (Enable) Catalyst Diagnosis (Comp) Heated catalyst (Enable) Heated catalyst (Comp) Evaporative purge system (Enable) Evaporative purge system (Comp) Secondary air system (Enable) Secondary air system (Comp) A/C system refrigerant (Enable) A/C system refrigerant (Comp) Oxygen sensor (Enable) Oxygen sensor (Comp) O2 Heater Diagnosis (Enable) O2 Heater Diagnosis (Comp) EGR system (Enable) EGR system (Comp) Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. Time while MIL lighted Time since DTC cleared Type of fuel Relative Accelera. Pos. Referential value (at idling) YES NO N/A N/A NO NO N/A N/A N/A N/A YES NO YES NO YES NO 13.789 22 0.976 2 Ambient air temperature 32 13 13 0 GAS 0 Unit of measure V % % C % % % % min min %
EN(H4SO)(diag)-38

4. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Freeze Frame Data Display}. A list of the support data is shown in the following table.
Contents DTCs of freeze frame data Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing advance for #1 cylinder Intake air temperature signal Intake air amount Throttle position signal Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (bank 1 sensor 1) Oxygen sensor (Bank 1 Sensor 2) Elapsed time after engine start Target EGR EGR deviation Evaporative purge Fuel level signal Fuel tank pressure signal Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Display Freeze frame data Fuel system for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start Commanded EGR EGR Error Commanded Evap Purge Fuel Level Fuel Tank Pressure Atmosphere Pressure Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. Unit of measure % C or F % % mmHg, kPa, inHg or psig rpm km/h or MPH C or F g/s or lb/m % V % sec % % % % mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig V % % C or F % % % %
5. V.I.N REGISTRATION
1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {Entry VIN}. 5) Perform the procedures shown on the display screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4SO)(diag)-39
Read Diagnostic Trouble Code (DTC)

10.Read Diagnostic Trouble Code (DTC)

A: OPERATION
1. SUBARU SELECT MONITOR (NORMAL MODE)
1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display}. 5) On the Diagnostic Code(s) Display display screen, select the {Temporary Diagnostic Code(s)} or {Memorized Diagnostic Code(s)}. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)-80, List of Diagnostic Trouble Code (DTC).>
3. GENERAL SCAN TOOL

Refer to data denoting emission-related powertrain DTC. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)-80, List of Diagnostic Trouble Code (DTC).> NOTE: Refer to general scan tool manufacturers instruction manual to access powertrain DTC (MODE $03).
2. SUBARU SELECT MONITOR (OBD MODE)

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Diagnostic Code(s) Display}. 6) Make sure DTC is shown on the screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)-80, List of Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-40
Inspection Mode
11.Inspection Mode
A: PROCEDURE
Perform the diagnosis shown in the following DTC table. When performing the diagnosis not listed in List of Diagnostic Trouble Code (DTC), refer to the item on the drive cycle. <Ref. to EN(H4SO)(diag)-46, Drive Cycle.>
DTC P0031 P0032 P0037 P0038 P0077 P0083 P0102 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0137 P0138 P0140 P0182 P0183 P0197 P0198 P0222 P0223 P0327 P0328 P0335 P0336 P0340 P0341 P0447 P0448 P0452 P0453 P0458 P0462 P0463 P0500 P0512 P0513 P0600 Item HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit High (Bank 2) Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch A Circuit Low Throttle/Pedal Position Sensor/Switch A Circuit High O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) Fuel Temperature Sensor A Circuit Low Input Fuel Temperature Sensor A Circuit High Input Engine Oil Temperature Sensor Low Engine Oil Temperature Sensor High Throttle/Pedal Position Sensor/Switch B Circuit Low Throttle/Pedal Position Sensor/Switch B Circuit High Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) Crankshaft Position Sensor A Circuit Crankshaft Position Sensor A Circuit Range/Performance Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor) Camshaft Position Sensor A Circuit Range/Performance (Bank 1 or Single Sensor) Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission System Purge Control Valve Circuit Low Fuel Level Sensor A Circuit Low Fuel Level Sensor A Circuit High Vehicle Speed Sensor A Starter Request Circuit Incorrect Immobilizer Key Serial Communication Link Condition
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Inspection Mode
DTC P0604 P0605 P0607 P0638 P0700 P0851 P0852 P1152 P1153 P1160 P1400 P1420 P1491 P1560 P1570 P1571 P1572 P1574 P1576 P1577 P1578 P2101 P2102 P2109 P2122 P2123 P2127 P2128 P2135 P2138 P2227 P2228 P2229 Item Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (Mil Request) Park/Neutral Switch Input Circuit Low Park/Neutral Switch Input Circuit High O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Exhaust Gas Recirculation Flow Fuel Tank Pressure Control Sol. Valve Circuit High Positive Crankcase Ventilation (Blow-by) Function Problem Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle/Pedal Position Sensor A Minimum Stop Performance Throttle/Pedal Position Sensor/Switch D Circuit Low Input Throttle/Pedal Position Sensor/Switch D Circuit High Input Throttle/Pedal Position Sensor/Switch E Circuit Low Input Throttle/Pedal Position Sensor/Switch E Circuit High Input Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation Atmospheric Pressure Sensor Range/Performance Barometric Pressure Circuit Low Barometric Pressure Circuit High Condition
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Inspection Mode
1. PREPARATION FOR THE INSPECTION MODE

1) Check battery voltage is more than 12 V and fuel remains half [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)]. 2) Lift up the vehicle using a garage jack and place it on rigid racks, or drive the vehicle onto free rollers. WARNING: Before lifting up the vehicle, ensure parking brakes are applied. Do not use a pantograph jack in place of a rigid rack. Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front wheels. Before rotating the wheels, make sure that there is no one in front of the vehicle. Besides while the wheels are rotating, make sure that no one approaches the vehicle front side. Make sure that there is nothing around the wheels. For AWD model, pay special attention to all four wheels. While servicing, do not depress or release the clutch pedal or accelerator pedal quickly regardless of the engine speed. Quick operation may cause the vehicle to drop off the free roller. To prevent the vehicle from slipping due to vibration, do not place anything between rigid rack and the vehicle.
2. SUBARU SELECT MONITOR

1) Check that no DTC remains after clearing memory. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> 2) Warm up the engine. 3) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4SO)(diag)-7, PREPARATION TOOL, General Description.>
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4) Prepare PC with Subaru Select Monitor installed. 5) Connect the USB cable between SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 6) Connect the diagnosis cable to SDI. 7) Connect the delivery (test) mode connector (A) located under the glove box.
(A)
(A) PI-00201
(B)
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(A) Rigid rack (B) Free roller
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Inspection Mode
8) Connect SDI to data link connector located in the lower portion of the instrument panel (on the drivers side).

1) After performing the diagnostics and clearing the memory, check that no DTC remains. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> 2) Warm up the engine. 3) Connect the delivery (test) mode connector (A) located under the glove box.
(A) EN-02533
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 9) Start the PC. 10) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 11) On the Main Menu display screen, select the {Each System Check}. 12) On the System Selection Menu display screen, select the {Engine Control System}. 13) Click the [OK] button after the information of engine type has been displayed. 14) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure}. 15) When the Perform Inspection (Dealer Check) Mode? is shown on the screen, click the [Next] button. 16) Perform subsequent procedures as instructed on the display screen. If trouble still remains in the memory, the corresponding DTC appears on the display screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)-80, List of Diagnostic Trouble Code (DTC).> Release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this does not indicate a malfunction. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system. <Ref. to ABS(diag)-20, Clear Memory Mode.>
PI-00201
4) Connect the general scan tool to the data link connector located in the lower portion of the instrument panel (on the driver side). CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool.
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5) Start the engine. NOTE: Ensure the selector lever is placed in P range before starting. (AT model) Depress the clutch pedal when starting engine. (MT model) 6) Turn the neutral position switch to ON using select lever or shift lever. 7) Depress the brake pedal to turn the brake switch ON. (AT model) 8) Keep the engine speed in 2,500 3,000 rpm range for 40 seconds.
EN(H4SO)(diag)-44
Inspection Mode
9) Place the select lever or shift lever in D position (AT model) or 1st gear (MT model) and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: For AWD model, release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system. <Ref. to ABS(diag)-20, Clear Memory Mode.> 10) Using the general scan tool, check DTC and record the result(s). NOTE: For detailed operation procedures, refer to the general scan tool operation manual. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)-80, List of Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-45
Drive Cycle
12.Drive Cycle
A: PROCEDURE
For the troubleshooting, there are driving patterns described below. Driving in the specified pattern allows to diagnose malfunctioning items listed below. After the repair of the following trouble items, be sure to drive the vehicle with the specified drive patterns to check whether the function is resumed correctly.
1. PREPARATION FOR DRIVE CYCLE

1) Check battery voltage is more than 12 V and fuel remains half [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)]. 2) After performing the diagnostics and clearing the memory, check that no DTC remains. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> 3) Disconnect the delivery (test) mode connector. NOTE: Except for the water temperature specified at starting, be sure to carry out the diagnosis after the engine is warmed up. Perform the diagnosis twice if the DTC marked with *. After completing the first diagnosis, stop the engine and perform second diagnosis in same condition.
2. DRIVE CYCLE A DRIVE THE VEHICLE WITH 80 KM/H (50 MPH) FOR 20 MINUTES, AND THEN IDLE THE ENGINE FOR A MINUTE
DTC *P0125 *P0128 *P0133 *P0171 *P0172 *P0196 *P0301 *P0302 *P0303 *P0304 *P0420 *P0442 *P0451 *P0456 *P0457 *P0459 P1443 *P2096 *P2097 P2103 Item Insufficient Coolant Temperature for Closed Loop Fuel Control Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) System Too Lean (Bank 1) System Too Rich (Bank 1) Engine Oil Temperature Sensor Circuit Range/Performance Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Catalyst System Efficiency below Threshold (Bank 1) Evaporative Emission Control System Leak Detected (Small Leak) Evaporative Emission Control System Pressure Sensor Evaporative Emission Control System Leak Detected (Very Small Leak) Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Evaporative Emission System Purge Control Valve Circuit High Vent Control Solenoid Valve Function Problem Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Throttle Actuator Control Motor Circuit High Condition Coolant temperature at start is less than 20C (68F). Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Engine coolant temperature at engine start is less than 30C (86F). Engine coolant temperature at engine start is less than 30C (86F). Engine coolant temperature at engine start is less than 30C (86F). Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well.
EN(H4SO)(diag)-46
Drive Cycle
3. DRIVE CYCLE B 10 MINUTES IDLING

NOTE: Drive the vehicle at 10 km/h (6 MPH) or more before diagnosis.
DTC *P0126 *P0171 *P0172 *P0301 *P0302 *P0303 *P0304 *P0464 *P0506 *P0507 *P2096 *P2097 P2103 Item Insufficient Engine Coolant Temperature for Stable Operation System Too Lean (Bank 1) System Too Rich (Bank 1) Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Fuel Level Sensor Circuit Intermittent Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Throttle Actuator Control Motor Circuit High Condition Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well.
4. DRIVE CYCLE C DRIVE THE VEHICLE WITH FOLLOWING DRIVE PATTERNS

(H)
(C) 97 (60) (D) 64 (40) (F) (G)
(B)
(E)
(A) 0 50 100 150 (I) EN-00842
(A) (B) (C)
Idle the engine for 10 seconds or more. Accelerate to 97 km/h (60 MPH) within 20 seconds. Drive the vehicle at 97 km/h (60 MPH) for 20 seconds.
(D) (E) (F)
Decelerate with fully closed throttle to 64 km/h (40 MPH). Drive the vehicle at 64 km/h (40 MPH) for 20 seconds. Accelerate to 97 km/h (60 MPH) within 10 seconds.
(G) (H) (I)
Stop vehicle with the throttle fully closed. Vehicle speed km/h (MPH) Sec.
EN(H4SO)(diag)-47
Drive Cycle
DTC P0026 P0028 *P0030 *P0068 P0076 P0082 *P0101 P0134 *P0139 *P0171 *P0172 *P0301 *P0302 *P0303 *P0304 *P0400 P1492 P1493 P1494 P1495 P1496 P1497 P1498 P1499 *P2096 *P2097 P2103 Item Intake Valve Control Solenoid Circuit Range/Performance (Bank 1) Intake Valve Control Solenoid Circuit Range/Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) MAP/MAF - Throttle Position Correlation Intake Valve Control Solenoid Circuit Low (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Mass or Volume Air Flow Circuit Range/Performance O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) System Too Lean (Bank 1) System Too Rich (Bank 1) Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Exhaust Gas Recirculation Flow EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input) Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Throttle Actuator Control Motor Circuit High Condition Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well.
5. DRIVE CYCLE D
Drift Diagnosis 1) Make sure that the engine coolant temperature at engine starting is less than 30C (86F). 2) Make sure that fuel remains 10 2 (2.6 US gal, 2.2 Imp gal) or more and the battery voltage is 10.9 V or more. 3) Start the engine, and check that the engine coolant temperature increases by 10C (50F) or more, and reaches 75C (167F) or more, when the engine is warmed up. 4) Idle the engine for 120 seconds or more in the condition of step 3. Stuck Diagnosis 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> 3) Drive for approximately 50 2 (13.2 US gal, 11 Imp gal) of fuel. NOTE: It is acceptable to drive the vehicle intermittently. Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
DTC *P0181 Item Fuel Temperature Sensor A Circuit Range/Performance Condition
EN(H4SO)(diag)-48
Drive Cycle
6. DRIVE CYCLE E
1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> 3) Drive for approximately 30 2 (7.9 US gal, 6.6 Imp gal) of fuel. NOTE: It is acceptable to drive the vehicle intermittently. Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
DTC *P0461 Item Fuel Level Sensor A Circuit Range/Performance Condition
7. DRIVE CYCLE F
1) Make sure that the engine coolant temperature at engine starting is less than 30C (86F). 2) Start the engine, and warm it up until engine coolant temperature increases over 95C (203F). 3) Idle the engine for more than 10 minutes in the condition of step 2. NOTE: Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
DTC *P0111 Item Intake Air Temperature Sensor 1 Circuit Range/Performance Condition
8. DRIVE CYCLE H
1) Perform the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> 2) With the ignition switch ON, read the engine coolant temperature, intake air temperature and fuel temperature. <Ref. to EN(H4SO)(diag)-34, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> 3) If the values from step 2) satisfy the following two conditions, start the engine. Condition: |Engine coolant temperature intake air temperature | d 5C (41F) |Engine coolant temperature fuel temperature | d 2C (36F) NOTE: If the conditions are not satisfied, turn the ignition switch to OFF and wait until the parameters are satisfied. Start AT vehicles in the P range, and MT vehicles in the neutral position. 4) Idle the engine for 1 minute under the conditions in step 3).
DTC
*P1602
Item Control Module Programming Error
Condition
EN(H4SO)(diag)-49
Clear Memory Mode

13.Clear Memory Mode

A: OPERATION
NOTE: When Clear Memory Mode is performed in OBD mode of Subaru Select Monitor, only DTCs are cleared.

For clear memory procedures using the general scan tool, refer to General Scan Tool Instruction Manual. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. For this reason, start the engine after 10 seconds or more have elapsed since the ignition switch was turned to ON.

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {Clearing Memory}. 5) When the Clear Memory? is shown on the screen, click the [Yes] button. 6) When Done and Turn off the ignition switch. are shown on the display screen, turn the ignition switch to OFF. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine. For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Clear Diagnostic Code}. 6) When the Clear Diagnostic Code? is shown on the screen, click the [Yes] button. 7) When Done and Turn off the ignition switch. are shown on the display screen, turn the ignition switch to OFF. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine. For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4SO)(diag)-50
Compulsory Valve Operation Check Mode

14.Compulsory Valve Operation Check Mode

A: OPERATION
EN-05692
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 7) Start the PC. 8) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 9) On the Main Menu display screen, select the {Each System Check}. 10) On the System Selection Menu display screen, select the {Engine Control System}. 11) Click the [OK] button after the information of engine type has been displayed. 12) On the Engine Diagnosis display screen, select the {System Operation Check Mode}. 13) On the System Operation Check Mode display screen, select the {Actuator ON/OFF Dr.}. 14) Select the desired compulsory actuator on the Actuator ON/OFF Operation display screen and click the [Next] button. 15) Clicking the [End] button completes the compulsory valve operation check mode. The display will then return to the Actuator ON/OFF Operation screen. A list of the support data is shown in the following table.
Description Compulsory fuel pump relay operation check Compulsory purge control solenoid valve operation check Compulsory radiator fan relay operation check Compulsory air conditioning relay operation check Display Fuel Pump Relay CPC Solenoid Valve Radiator Fan Relay A/C Compressor Relay
(A)
Compulsory pressure control solePCV Solenoid Valve noid valve operation check Compulsory drain valve operation Vent. Solenoid Valve check
PI-00201
NOTE: The following parts will be displayed but not functional.

Display EGR Solenoid Valve ASV Solenoid Valve FICD Solenoid Pressure Switching Sol.1 Pressure Switching Sol.2 AAI Solenoid Valve Fuel Tank Sensor Control Valve Turbocharger Wastegate Solenoid EXH. Bypass Control Permit Flag Secondary Air Combi Valve 1
EN-02533
For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4SO)(diag)-51
System Operation Check Mode

15.System Operation Check Mode

A: OPERATION
12) The following items are displayed on the monitor.

Display Actuator ON/OFF Operation Immobilizer System Fuel Pump Control Fixed Idle Ignition Timing Idle Speed Control Injector Control EGR Valve Control Injector Control
1. FUEL PUMP CONTROL (OFF DRIVE)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fuel Pump Control}. 2) On the Fuel Pump Control display screen, select the {OFF Operation}. 3) On the Start the Engine display screen, start the engine and click the [OK] button. 4) On the OFF Drive display screen, click the [Execution] button and execute the OFF drive. 5) Click the [Cancel] button to stop the OFF drive. 6) Click the [ Exit] button to end the OFF drive. The screen will return to the Fuel Pump Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN-05692
2. FUEL PUMP CONTROL (ON/OFF DRIVE)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fuel Pump Control}. 2) On the Fuel Pump Control display screen, select the {ON/OFF Dr.}. 3) On the Turn Ignition Switch ON with Engine OFF display screen, turn the ignition switch to ON and click the [OK] button. 4) On the ON/OFF Dr. display screen, click the [Execution] button and execute the ON/OFF drive. 5) Click the [Cancel] button to stop the ON/OFF drive. 6) Click the [ Exit] button to end the ON/OFF drive. The screen will return to the Fuel Pump Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN-02533
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 8) On the Main Menu display screen, select the {Each System Check}. 9) On the System Selection Menu display screen, select the {Engine Control System}. 10) Click the [OK] button after the information of engine type has been displayed. 11) On the Engine Diagnosis display screen, select the {System Operation Check Mode}.
EN(H4SO)(diag)-52

3. IDLING IGNITION TIMING FIXED

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fixed Idle Ignition Timing}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) On the Fixed Idle Ignition Timing display screen, click the [Execution] button and execute the idling ignition timing fixed. 4) Click the [Cancel] button to stop the idling ignition timing fixed. 5) Click the [ Exit] button to end the idling ignition timing fixed. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
5. INJECTOR CONTROL. (INJECTION STOP MODE)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Injector Control}. 2) On the Injector Control display screen, select the {Injection Stop Mode}. 3) On the Injection Stop Mode display screen, select the fuel injector to be stopped. 4) On the Start the Engine display screen, start the engine and click the [OK] button. 5) On the Fuel Injector # display screen, click the [Execution] button and execute the injection stop mode. 6) Click the [Cancel] button to stop the injection stop mode. 7) Click the [ Exit] button to return the Injection Stop Mode display screen. 8) On the Injection Stop Mode display screen, click the [Return] button to end the Injection Stop Mode. The screen will return to the Injector Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
4. IDLE SPEED CONTROL

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Idle Speed Control}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) In the Idle Speed Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in a range between 500 rpm 2,000 rpm, in increments of 50 rpm. However, the engine speed that can actually be controlled will vary depending on the vehicle. 4) Click the [Cancel] button to stop the idle speed control. 5) Click the [ Exit] button to end the idle speed control. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
6. INJECTOR CONTROL. (INJECTION QUANTITY CONTROL)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Injector Control}. 2) On the Injector Control display screen, select the {Injection Quantity Control}. 3) On the Start the Engine display screen, start the engine and click the [OK] button. 4) In the Injection Quantity Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in a range between 0 20%, in increments of 1%. 5) Click the [Cancel] button to stop the injection quantity control. 6) Click the [ Exit] button to end the injection quantity control. The screen will return to the Injector Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4SO)(diag)-53

7. EGR VALVE CONTROL

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {EGR Valve Control}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) In the EGR Valve Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in increments of 1 STEP. However, the STEP number that can actually be controlled will vary depending on the vehicle. 4) Click the [Cancel] button to stop the EGR valve control. 5) Click the [ Exit] button to end the EGR valve control. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4SO)(diag)-54
Malfunction Indicator Light

16.Malfunction Indicator Light

A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4SO)(diag)-56, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> p 2. Malfunction indicator light does not come on. <Ref. to EN(H4SO)(diag)-57, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.> p 3. Malfunction indicator light does not go off. <Ref. to EN(H4SO)(diag)-59, MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF, Malfunction Indicator Light.> p 4. Malfunction indicator light does not blink. <Ref. to EN(H4SO)(diag)-60, MALFUNCTION INDICATOR LIGHT DOES NOT BLINK, Malfunction Indicator Light.> p 5. Malfunction indicator light remains blinking. <Ref. to EN(H4SO)(diag)-62, MALFUNCTION INDICATOR LIGHT REMAINS BLINKING, Malfunction Indicator Light.>
EN(H4SO)(diag)-55

B: ACTIVATION OF MALFUNCTION INDICATOR LIGHT

1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit. <Ref. to EN(H4SO)(diag)-57, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>
3) If the diagnostic system detects a misfire which could damage the catalyst, the malfunction indicator light will blink at a cycle of 1 Hz.
(1) (2) (3) (4) (6) (5) EN-01680
CHECK ENGINE
(1) (2) (3) (4) (5) (6)
ON OFF Ignition switch ON Engine start Misfire start 1 second
(A)
EN-05736
2) After starting the engine, the malfunction indicator light goes out. If it does not go off, either the engine or emission control system has malfunction.
(1) (3) (4) (2) (3) (4) (5) (6) EN-01679
4) Turn the ignition switch to OFF and connect the delivery (test) mode connector. (1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light illuminates. (2) After the engine starts, malfunction indicator light blinks in a cycle of 0.5 Hz. (During diagnosis) (3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Malfunction indicator light illuminates if faulty.
(1) (2) (4)
(1) (2) (3) (4) (5) (6)
No faulty Trouble occurs ON OFF Ignition switch ON Engine start
(3)
EN-01681
(1) (2) (3) (4)
ON OFF Ignition switch ON 1 second
EN(H4SO)(diag)-56

C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON

DIAGNOSIS: The malfunction indicator light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not illuminate. WIRING DIAGRAM:
B72 No.5 1
IGNITION SWITCH SBF-6 3 MAIN SBF
BATTERY
COMBINATION METER i10 16 i3 8 B38 11
B136
ECM
B72
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
B38
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05697
EN(H4SO)(diag)-57

Step Check Yes CHECK OUTPUT SIGNAL OF ECM. Is the voltage 10 V or more? Go to step 5. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 11 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 3. COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the combination meter. <Ref. to IDI-22, Combination Meter.> 3) Disconnect the connector from ECM and combination meter. 4) Measure the resistance of harness between ECM and combination meter connector. Connector & terminal (B136) No. 11 (i10) No. 16: Is there poor contact in combi- Repair the poor nation meter connector? contact of combination meter connector. CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more? Replace the comTION METER AND IGNITION SWITCH CONbination meter NECTOR. board. <Ref. to IDI1) Turn the ignition switch to ON. 22, Combination 2) Measure the voltage between combination Meter.> meter connector and chassis ground. Connector & terminal (i10) No. 3 (+) Chassis ground (): CHECK POOR CONTACT. Check for poor contact of combination meter connector. No Go to step 2.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and combination meter connector Poor contact of coupling connector Go to step 4.
CHECK POOR CONTACT. Check for poor connection by shaking or pulling ECM harness. CHECK ECM CONNECTOR. Check the connection of ECM connector.
Does the malfunction indicator Repair the poor light illuminate? contact of ECM connector. Is the ECM connector correctly Replace the ECM. Repair the connecconnected? <Ref. to tion of ECM conFU(H4SO)-39, nector. Engine Control Module (ECM).>
Check the following item and repair if necessary. NOTE: Blown out of fuse (No. 5) Open or short circuit in harness between fuse (No. 5) and battery terminal Poor contact in ignition switch connector Go to step 6.
EN(H4SO)(diag)-58

D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF

DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor display. WIRING DIAGRAM:
B72 No.5 1
BATTERY
COMBINATION METER i10 16 i3 8 B38 11
B136
ECM
B72
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
B38
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05697
Step CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Turn the ignition switch to ON.
Check Yes Does the malfunction indicator Repair the short light illuminate? circuit of harness between ECM and combination meter connector.
No Replace the ECM. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).>
EN(H4SO)(diag)-59

E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK

DIAGNOSIS: The malfunction indicator light circuit is open or shorted. The delivery (test) mode connector circuit is open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during Inspection Mode. WIRING DIAGRAM:
B72 No.5 1 3 IGNITION SWITCH SBF-6 MAIN SBF BATTERY
COMBINATION METER i10 16
DELIVERY (TEST) MODE CONNECTOR 1 i3 8 B38 C11 B27 B75 1 B76
B122
* * *
C6 : TERMINAL No. OPTIONAL ARRANGEMENT
B: B135
C: B136
ECM
B75 1 2
B72
i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
B38
B122
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8
B:
B135
C:
B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-05698
EN(H4SO)(diag)-60

Step Check Yes CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 2. CATOR LIGHT. light illuminate? 1) Turn the ignition switch to OFF. 2) Disconnect the delivery (test) mode connector. 3) Turn the ignition switch to ON. (engine OFF) No Repair the malfunction indicator light circuit. <Ref. to EN(H4SO)(diag)57, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.> Go to step 3.
Does the malfunction indicator CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. light illuminate? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Turn the ignition switch to ON. CHECK HARNESS BETWEEN ECM AND DE- Is the resistance less than 1 :? LIVERY (TEST) MODE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and delivery (test) mode connector. Connector & terminal (B76) No. 1 (B136) No. 6: (B75) No. 1 (B135) No. 27:
CHECK POOR CONTACT. Check for poor contact of the ECM connector.
Repair the short circuit of harness between ECM and combination meter connector. Go to step 4. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and delivery (test) mode connector Poor contact in joint connector Repair the poor Replace the ECM. contact of ECM <Ref. to connector. FU(H4SO)-39, Engine Control Module (ECM).>
EN(H4SO)(diag)-61

F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING

DIAGNOSIS: The delivery (test) mode connector circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when delivery (test) mode connector is not connected. WIRING DIAGRAM:
COMBINATION METER i10 16
DELIVERY (TEST) MODE CONNECTOR 1 i3 8 B38 C11 B27 B75 1 B76
B122
* * *
C6 : TERMINAL No. OPTIONAL ARRANGEMENT
B: B135
C: B136
ECM
B75 1 2
B72
i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
B38
B122
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8
B:
B135
C:
B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-05698
EN(H4SO)(diag)-62

Step Check Yes CHECK DELIVERY (TEST) MODE CONNEC- Does the malfunction indicator Go to step 2. TOR. light blink? 1) Disconnect the delivery (test) mode connector. 2) Turn the ignition switch to ON. No System is normal. NOTE: Malfunction indicator light blinks when delivery (test) mode connector is connected. CHECK HARNESS BETWEEN ECM AND DE- Is the resistance less than 5 :? Repair the short Replace the ECM. LIVERY (TEST) MODE CONNECTOR. circuit of harness <Ref. to 1) Turn the ignition switch to OFF. between ECM and FU(H4SO)-39, 2) Disconnect the connectors from ECM. Engine Control delivery (test) 3) Measure the resistance of harness between mode connector. Module (ECM).> ECM and chassis ground. Connector & terminal (B135) No. 27 Chassis ground:
EN(H4SO)(diag)-63
Diagnostics for Engine Starting Failure

17.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Check of the fuel amount p 2. Inspection of starter motor circuit. <Ref. to EN(H4SO)(diag)-65, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> p 3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO)(diag)-69, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> p 4. Inspection of ignition control system. <Ref. to EN(H4SO)(diag)-71, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> p 5. Inspection of fuel pump circuit. <Ref. to EN(H4SO)(diag)-74, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.> p 6. Inspection of fuel injector circuit. <Ref. to EN(H4SO)(diag)-76, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(H4SO)(diag)-64

B: STARTER MOTOR CIRCUIT

CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, Inspection Mode.>. WIRING DIAGRAM:
BATTERY No. 21 2 B72 15 13 IGNITION SWITCH 3 SBF-6 MAIN SBF
STARTER RELAY B225
16
14
INHIBITOR SWITCH AT MT AT MT 11 12 B12 T3 9 6 T7 P R N D
B106 2
MT
CLUTCH START SWITCH
STARTER MOTOR (MAGNET)
AT
MT
M
AT B14 20 B136 ECM
B225 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
32
B106 1 2
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B72 1 2 3 4 5 6
B12 1 2 3 4 5 6 7 8 9 10 11 12
T7 1 2 3 4 5 6 7 8 9
EN-06830
EN(H4SO)(diag)-65

Step CHECK BATTERY. Check the battery voltage. CHECK OPERATION OF STARTER MOTOR. NOTE: Check the security alarm is not sounding. CHECK DTC. Check Is the voltage 12 V or more? Does the starter motor operate? Is DTC displayed? <Ref. to EN(H4SO)(diag)-40, OPERATION, Read Diagnostic Trouble Code (DTC).> Yes Go to step 2. Go to step 3. No Charge or replace the battery. Go to step 4.
1 2
Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).>
CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage 10 V or more? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from starter motor. 3) Turn the ignition switch to START. 4) Measure the voltage between the starter motor connector and the engine ground. Connector & terminal (B14) No. 1 (+) Engine ground (): NOTE: For AT model, place the select lever in P range or N range. For MT model, depress the clutch pedal. CHECK HARNESS BETWEEN BATTERY Is the voltage 10 V or more? AND IGNITION SWITCH CONNECTOR. 1) Disconnect the connector from ignition switch. 2) Measure the power supply voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 3 (+) Chassis ground ():
Check the starter motor. <Ref. to SC(H4SO)-6, Starter.>
The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 5.
Go to step 6.
CHECK IGNITION SWITCH. Is the resistance less than 5 :? Go to step 7. 1) Disconnect the connector from ignition switch. 2) Measure the resistance between ignition switch terminals after turning the ignition switch to START position. Terminals No. 2 No. 3:
Check the following item and repair if necessary. Blown out of fuse Open or ground short circuit of harness between ignition switch connector and battery Replace the ignition switch. <Ref. to SL-49, REPLACEMENT, Ignition Key Lock.>
EN(H4SO)(diag)-66

Step CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from starter relay. 3) Connect the connector to ignition switch. 4) Measure the input voltage between starter relay connector and chassis ground after turning the ignition switch to START position. Connector & terminal (B225) No. 13 (+) Chassis ground (): (B225) No. 15 (+) Chassis ground (): CHECK STARTER RELAY. 1) Connect the battery to starter relay terminals No. 15 and No. 16. 2) Measure the resistance between starter relay terminals. Terminals No. 13 No. 14: CHECK HARNESS BETWEEN ECM AND STARTER RELAY. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness connector between ECM and starter relay. Connector & terminal (B225) No. 16 (B136) No. 20: CHECK TRANSMISSION TYPE. CHECK ECM INPUT VOLTAGE. 1) Turn the ignition switch to START. 2) Measure the input voltage between ECM and chassis ground. Connector & terminal (B136) No. 32 (+) Chassis ground (): CHECK HARNESS BETWEEN STARTER RELAY AND INHIBITOR SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from inhibitor switch. 3) Measure the resistance of harness between the starter relay and inhibitor switch. Connector & terminal (B225) No. 14 (T7) No. 9: Check Is the voltage 10 V or more? Yes Go to step 8. No Check the following item and repair if necessary. Blown out of fuse Open or short circuit to ground in harness between starter relay and ignition switch connector Replace the starter relay.
Repair the open circuit of harness between ECM and starter relay connector.
10 11
Is the transmission type AT? Is the voltage 10 V or more?
Go to step 11. Go to step 12.
Go to step 15. Repair the open circuit of harness between ECM and ignition switch connector. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between starter relay connector and inhibitor switch connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between inhibitor switch connector and starter motor Poor contact of coupling connector
12
13
Is the resistance less than 1 :? Go to step 14. CHECK HARNESS BETWEEN INHIBITOR SWITCH AND STARTER MOTOR. Measure the resistance of harness between the inhibitor switch and starter motor. Connector & terminal (T7) No. 6 (B14) No. 1:
EN(H4SO)(diag)-67

Step CHECK INHIBITOR SWITCH. 1) Place the select lever in P range or N range. 2) Measure the resistance between inhibitor switch terminals. Terminals No. 6 No. 9: Check Yes Is the resistance less than 1 :? Check the engine control module (ECM) power supply and ground line. <Ref. to EN(H4SO)(diag)69, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> Is the voltage 10 V or more? Go to step 16. No Replace the inhibitor switch. <Ref. to 4AT-46, Inhibitor Switch.>
14
15
16
17
18
CHECK HARNESS BETWEEN IGNITION SWITCH AND CLUTCH START SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from clutch start switch. 3) Turn the ignition switch to START. 4) Measure the voltage between the clutch start switch and chassis ground. Connector & terminal (B106) No. 1 (+) Chassis ground (): Is the resistance less than 1 :? CHECK CLUTCH START SWITCH. Measure the resistance between clutch start switch terminals while depressing the clutch pedal. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? CLUTCH START SWITCH. Measure the resistance of harness between ECM and clutch start switch. Connector & terminal (B136) No. 32 (B106) No. 2: CHECK HARNESS BETWEEN STARTER RE- Is the resistance less than 1 :? LAY AND STARTER MOTOR. Measure the resistance of harness between starter relay connector and starter motor. Connector & terminal (B225) No. 14 (B14) No. 1:
Repair the open circuit in harness between ignition switch connector and clutch start switch.
Go to step 17.
Replace the clutch start switch. <Ref. to CL-37, Clutch Switch.>
Go to step 18.
Repair the open circuit of harness between the ECM and clutch start switch. Repair the open circuit of the harness between starter relay connector and starter motor.
Check the engine control module (ECM) power supply and ground line. <Ref. to EN(H4SO)(diag)69, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>
EN(H4SO)(diag)-68

C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM)
CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 3 5 6 4 2 1 B47 No. 12 1 C23 B2 A7 B5 B19 3 TO IGNITION COIL & IGNITOR ASSY SBF-7 No. 13 B72 IGNITION SWITCH SBF-6 MAIN SBF
BATTERY
A: B134
E
B: B135 ECM C: B136 D: B137 A5 D1 D2 D3 D7 52 B21 E2
36
34
35
37
E
B: B135
B72
B47
B21
A: 1 8 9 18 19 28 29 2 10 20 30
B134
C:
B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06831
EN(H4SO)(diag)-69

Step Check Yes CHECK MAIN RELAY. Is the resistance less than 1 :? Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the main relay. 3) Connect the battery to main relay terminals No. 1 and No. 2. 4) Measure the resistance between main relay terminals. Terminals No. 3 No. 5: No. 4 No. 6: CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? Go to step 3. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 5 (+) Chassis ground (): (B135) No. 19 (+) Chassis ground (): CHECK INPUT VOLTAGE OF MAIN RELAY. Measure the voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 2 (+) Chassis ground (): (B47) No. 5 (+) Chassis ground (): (B47) No. 6 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Install the main relay. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 23 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Connect the connector to ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): Is the voltage 10 V or more? Go to step 4. No Replace the main relay. <Ref. to FU(H4SO)-40, Main Relay.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Repair the open or ground short circuit of harness of power supply circuit.
Go to step 5.
Repair the open or ground short circuit of harness of power supply circuit.
Go to step 6.
Repair the open or ground short circuit of harness between ECM and main relay connector.
Check ignition control system. <Ref. to EN(H4SO)(diag)71, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and main relay connector Poor contact of main relay connector
EN(H4SO)(diag)-70

D: IGNITION CONTROL SYSTEM

CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM
26 6 19 18
B225 RELAY BLOCK 15A 2 1
B47
MAIN RELAY BATTERY SBF-7 5
47 33 32 49 IGNITION COIL & IGNITOR ASSY 3 4 1 2 3 4 1 2
B21 E2
E12
E12
B47
B225 1 3 5 7 2 4 6 8 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
B21
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05701
EN(H4SO)(diag)-71

Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cylin1) Remove the plug cord cap from each spark der? plug. 2) Install a new spark plug on plug cord cap. CAUTION: Do not remove the spark plug from engine. 3) Contact the spark plugs thread portion to the engine. 4) While opening the throttle valve fully, crank the engine to check that spark occurs at each cylinder. CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage 10 V or more? NITION COIL AND IGNITOR ASSEMBLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the ignition coil & ignitor assembly. 3) Turn the ignition switch to ON. 4) Measure the voltage between ignition coil and ignitor assembly connector and engine ground. Connector & terminal (E12) No. 2 (+) Engine ground (): Yes No Check fuel pump Go to step 2. system. <Ref. to EN(H4SO)(diag)74, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
Go to step 3.
CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 :? Go to step 4. NITION COIL AND IGNITOR ASSEMBLY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between the ignition coil and ignitor assembly connector and the ECM. Connector & terminal (E12) No. 3 (B137) No. 6: (E12) No. 3 (B137) No. 26:
CHECK IGNITION COIL AND IGNITOR ASSEMBLY. 1) Remove the spark plug cords. 2) Measure the resistance between spark plug cord contact portions to check secondary coil. Terminals No. 1 No. 2: No. 3 No. 4: CHECK INPUT SIGNAL FOR IGNITION COIL AND IGNITOR ASSEMBLY. 1) Connect the connector to the Ignition coil and ignitor assembly. 2) Check if voltage varies synchronously with engine speed when cranking, while monitoring voltage between ignition coil and ignitor assembly connector and engine ground. Connector & terminal (E12) No. 1 (+) Engine ground (): (E12) No. 4 (+) Engine ground ():
Is the resistance between 10 and Go to step 5. 15 k:?
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ignition coil and ignitor assembly, and main relay connector Poor contact of coupling connector Blown out of fuse Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and ignition coil and ignitor assembly connector Poor contact of coupling connector Replace the ignition coil and ignitor assembly. <Ref. to IG(H4SO)-6, Ignition Coil and Ignitor Assembly.>
Does the voltage vary 10 V or more?
Go to step 6.
Replace the ignition coil and ignitor assembly. <Ref. to IG(H4SO)-6, Ignition Coil and Ignitor Assembly.>
EN(H4SO)(diag)-72

Step Check CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 :? NITION COIL AND IGNITOR ASSEMBLY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Disconnect the connector from the ignition coil & ignitor assembly. 4) Measure the resistance of harness between ECM and ignition coil and ignitor assembly connector. Connector & terminal (B137) No. 18 (E12) No. 1: (B137) No. 19 (E12) No. 4: CHECK HARNESS BETWEEN ECM AND IG- Is the resistance 1 M: or NITION COIL AND IGNITOR ASSEMBLY more? CONNECTOR. Measure the resistance of harness between ECM and engine ground. Connector & terminal: (B137) No. 18 Engine ground: (B137) No. 19 Engine ground: Yes Go to step 7. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and ignition coil and ignitor assembly connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and ignition coil and ignitor assembly connector.
Repair the poor contact of ECM connector.
EN(H4SO)(diag)-73

E: FUEL PUMP CIRCUIT

CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
No. 11
B72 FUEL PUMP RELAY 1 4 3 2 B362 No. 12 1
BATTERY
12
B136
ECM
B97 20 R1
FUEL PUMP 5 3 5 R67 R46 SD SD 1 2 R142
FUEL PUMP CONDENSER
6 R58
SD
: SEDAN MODEL
B362
B72
R142
B97
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2
3 4
1 2 3 4 5 6
1 2
5 7 8 6
EN-06832
Step Check CHECK OPERATING SOUND OF FUEL Does the fuel pump emit operPUMP. ating sound? Make sure that the fuel pump operates for two seconds when turning the ignition switch to ON. NOTE: Fuel pump operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.>
Yes Check the fuel injector circuit. <Ref. to EN(H4SO)(diag)76, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
No Go to step 2.
EN(H4SO)(diag)-74

Step Check Yes CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 :? Go to step 3. 1) Turn the ignition switch to OFF. 2) Remove the fuel pump access hole lid. 3) Disconnect the connector from fuel pump. 4) Measure the resistance of harness connector between fuel pump and chassis ground. Connector & terminal (R58) No. 6 Chassis ground: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between fuel pump connector and chassis grounding terminal Poor contact of coupling connector Go to step 4.
CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage 10 V or more? 1) Turn the ignition switch to ON. 2) Measure the voltage of power supply circuit between fuel pump connector and chassis ground. Connector & terminal (R58) No. 5 (+) Chassis ground (): CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 :? AND FUEL PUMP RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel pump connector and fuel pump relay connector. Connector & terminal (R58) No. 5 (B362) No. 2:
Replace the fuel pump. <Ref. to FU(H4SO)-55, Fuel Pump.>
Go to step 5.
CHECK HARNESS BETWEEN FUEL PUMP AND FUEL PUMP RELAY CONNECTOR. Measure the resistance of harness between fuel pump and fuel pump relay connector. Connector & terminal (R58) No. 5 Chassis ground: CHECK FUEL PUMP RELAY. 1) Remove the fuel pump relay. 2) Connect the battery to fuel pump relay terminals No. 3 and No. 4. 3) Measure the resistance between terminals of fuel pump relay. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND FUEL PUMP RELAY CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and fuel pump relay connector. Connector & terminal (B136) No. 12 (B362) No. 3: CHECK POWER SUPPLY OF FUEL PUMP RELAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel pump relay connector and chassis ground. Connector & terminal (B362) No. 1 (+) Chassis ground (): (B362) No. 4 (+) Chassis ground ():
Go to step 6.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between fuel pump connector and fuel pump relay connector Poor contact of coupling connector Repair the short circuit of harness between fuel pump connector and fuel pump relay connector. Replace the fuel pump relay. <Ref. to FU(H4SO)-41, Fuel Pump Relay.>
Repair the open circuit of harness between ECM and fuel pump relay connector.
Repair the open or ground short circuit of power supply circuit.
EN(H4SO)(diag)-75

F: FUEL INJECTOR CIRCUIT

CAUTION: Check or repair only faulty parts. After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 6 4 2 1 B47
BATTERY SBF-7
B137
ECM
10
11 45 E6 2 1 B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 B21 E2 E17 FUEL INJECTOR No. 4
48
42
43
E5 2 1 2 1
E16 2 B21 1
FUEL INJECTOR No. 1
FUEL INJECTOR No. 2
FUEL INJECTOR No. 3
E5 E6 1 2
E16 E17
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
44
EN-06833
EN(H4SO)(diag)-76

Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit operTOR. ating sound? While cranking the engine, check each fuel injector emits operating sound. Use a sound scope or attach a screwdriver to the injector to listen to sounds for this check. CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more? JECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel injector connector and the engine ground. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground (): Yes No Check the fuel Go to step 2. pressure. <Ref. to ME(H4SO)-26, INSPECTION, Fuel Pressure.> Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay connector and fuel injector connector Poor contact of main relay connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and fuel injector connector. <Ref. to FU(H4SO)-30, Fuel Injector.> Replace the faulty fuel injector. <Ref. to FU(H4SO)-30, Fuel Injector.>
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. FUEL INJECTOR CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and fuel injector connector. Connector & terminal (B137) No. 8 (E5) No. 1: (B137) No. 9 (E16) No. 1: (B137) No. 10 (E6) No. 1: (B137) No. 11 (E17) No. 1: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal #1 (B137) No. 8 Chassis ground: #2 (B137) No. 9 Chassis ground: #3 (B137) No. 10 Chassis ground: #4 (B137) No. 11 Chassis ground: CHECK EACH FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between each fuel injector terminals. Terminals No. 1 No. 2: CHECK POOR CONTACT. Check for poor contact of the ECM connector. Is the resistance 1 M: or more? Go to step 5.
Is the resistance between 5 Go to step 6. 20 :?
Inspection using General Diagnostic Table<Ref. to EN(H4SO)(diag)300, INSPECTION, General Diagnostic Table.>
EN(H4SO)(diag)-77
Diagnostic Procedure for Subaru Select Monitor Communication

18.Diagnostic Procedure for Subaru Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS: Open or short circuit in data link connector TROUBLE SYMPTOM: Subaru Select Monitor communication failure WIRING DIAGRAM:
BATTERY No. 13
ECM A: B134 C: B136 D: B137
C16 C6
A5
D1
D2
D3
36
34
35
37
52 E2
* *
DATA LINK CONNECTOR 16 7 4 5 B40
B122
D7 B21
: TERMINAL No. OPTIONAL ARRANGEMENT
B122
B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 8 9 18 19 28 29
A: 2 10 20 30
B134
B21
1 2 3 4 5 6 7 8
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06834
EN(H4SO)(diag)-78

Step Check CHECK POWER SUPPLY CIRCUIT. Does SDI or general scan tool Connect the SDI (Subaru Diagnosis Interface) turn ON? or general scan tool to data link connector. CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 V or more? Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 16 (+) Chassis ground (): Yes Go to step 4. No Go to step 2.
CHECK HARNESS BETWEEN DATA LINK CONNECTOR AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between data link connector and chassis ground. Connector & terminal (B40) No. 4 Chassis ground: (B40) No. 5 Chassis ground:
CHECK HARNESS BETWEEN ECM AND DATA LINK CONNECTOR. 1) Disconnect the connectors from ECM, TCM, ABS CM, VDC CM, airbag CM and body integrated unit. CAUTION: When disconnecting the connector from airbag control module, always follow the precautions on AB section. <Ref. to AB-4, CAUTION, General Description.> 2) Measure the resistance of harness between ECM and data link connector. Connector & terminal (B136) No. 16 (B40) No. 7: CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or DATA LINK CONNECTOR. more? Measure the resistance between data link connector and chassis ground. Connector & terminal (B40) No. 7 Chassis ground:
Repair the power supply circuit. NOTE: In this case, repair the following item: Open or ground short circuit of harness between battery and data link connector Blown out of fuse (M/B No. 13) Is the resistance less than 5 :? Repair the poor Repair the harness contact of data link and connector. connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and data link connector Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Is the resistance less than 1 :? Go to step 5. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and data link connector
Go to step 3.
Repair the poor contact in the ECM or data link connector.
Repair the ground short circuit of harness between ECM and data link connector.
EN(H4SO)(diag)-79
List of Diagnostic Trouble Code (DTC)

19.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC P0026 Item Intake Valve Control Solenoid Circuit Range/Performance (Bank 1) Intake Valve Control Solenoid Circuit Range/Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) MAP/MAF - Throttle Position Correlation Intake Valve Control Solenoid Circuit Low (Bank 1) Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Intake Valve Control Solenoid Circuit High (Bank 2) Mass or Volume Air Flow Circuit Range/Performance Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Reference <Ref. to EN(H4SO)(diag)-87, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-89, DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-91, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-93, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-95, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-97, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-99, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-101, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-103, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-105, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-107, DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-109, DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-111, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-113, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-115, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-117, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-119, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0028
P0030
P0031
P0032
P0037
P0038
P0068
P0076
P0077
P0082
P0083
P0101
P0102
P0103
P0107
P0108
EN(H4SO)(diag)-80

DTC P0111 Item Intake Air Temperature Sensor 1 Circuit Range/Performance Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch A Circuit Low Throttle/Pedal Position Sensor/Switch A Circuit High Insufficient Coolant Temperature for Closed Loop Fuel Control Insufficient Engine Coolant Temperature for Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) System Too Lean (Bank 1) Reference <Ref. to EN(H4SO)(diag)-121, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-123, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-125, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-127, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-129, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-131, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-133, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-135, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-136, DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-138, DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-139, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-141, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-143, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-145, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-147, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-149, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-151, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-153, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-155, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0112
P0113
P0117
P0118
P0122
P0123
P0125
P0126
P0128
P0131
P0132
P0133
P0134
P0137
P0138
P0139
P0140
P0171
EN(H4SO)(diag)-81

DTC P0172 P0181 Reference <Ref. to EN(H4SO)(diag)-156, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Temperature Sensor A Circuit <Ref. to EN(H4SO)(diag)-158, DTC P0181 FUEL TEMPERATURE SENSOR Range/Performance A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Temperature Sensor A Circuit <Ref. to EN(H4SO)(diag)-160, DTC P0182 FUEL TEMPERATURE SENSOR Low Input A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Temperature Sensor A Circuit <Ref. to EN(H4SO)(diag)-162, DTC P0183 FUEL TEMPERATURE SENSOR High Input A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Oil Temperature Sensor Cir<Ref. to EN(H4SO)(diag)-164, DTC P0196 ENGINE OIL TEMPERATURE cuit Range/Performance SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Oil Temperature Sensor Low <Ref. to EN(H4SO)(diag)-166, DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Oil Temperature Sensor High <Ref. to EN(H4SO)(diag)-168, DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/Switch <Ref. to EN(H4SO)(diag)-170, DTC P0222 THROTTLE/PEDAL POSITION B Circuit Low SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/Switch <Ref. to EN(H4SO)(diag)-172, DTC P0223 THROTTLE/PEDAL POSITION B Circuit High SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 1 Misfire Detected <Ref. to EN(H4SO)(diag)-173, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 2 Misfire Detected <Ref. to EN(H4SO)(diag)-173, DTC P0302 CYLINDER 2 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 3 Misfire Detected <Ref. to EN(H4SO)(diag)-173, DTC P0303 CYLINDER 3 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 4 Misfire Detected <Ref. to EN(H4SO)(diag)-174, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 1 Circuit Low (Bank 1 <Ref. to EN(H4SO)(diag)-180, DTC P0327 KNOCK SENSOR 1 CIRCUIT or Single Sensor) LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 1 Circuit High (Bank 1 <Ref. to EN(H4SO)(diag)-182, DTC P0328 KNOCK SENSOR 1 CIRCUIT or Single Sensor) HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft Position Sensor A Circuit <Ref. to EN(H4SO)(diag)-184, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft Position Sensor A Circuit <Ref. to EN(H4SO)(diag)-186, DTC P0336 CRANKSHAFT POSITION SENRange/Performance SOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Camshaft Position Sensor A Circuit <Ref. to EN(H4SO)(diag)-188, DTC P0340 CAMSHAFT POSITION SENSOR (Bank 1 or Single Sensor) A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Camshaft Position Sensor A Circuit <Ref. to EN(H4SO)(diag)-190, DTC P0341 CAMSHAFT POSITION SENSOR Range/Performance (Bank 1 or Single A CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Sensor) Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Exhaust Gas Recirculation Flow <Ref. to EN(H4SO)(diag)-192, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Catalyst System Efficiency below <Ref. to EN(H4SO)(diag)-194, DTC P0420 CATALYST SYSTEM EFFICIENCY Threshold (Bank 1) BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Item System Too Rich (Bank 1)
P0182
P0183
P0196
P0197 P0198 P0222
P0223
P0301 P0302 P0303 P0304 P0327
P0328
P0335
P0336
P0340
P0341
P0400 P0420
EN(H4SO)(diag)-82

DTC P0442 Item Evaporative Emission Control System Leak Detected (Small Leak) Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission Control System Leak Detected (Very Small Leak) Evaporative Emission Control System Leak Detected (Fuel Cap Loose/ Off) Evaporative Emission System Purge Control Valve Circuit Low Evaporative Emission System Purge Control Valve Circuit High Fuel Level Sensor A Circuit Range/ Performance Fuel Level Sensor A Circuit Low Fuel Level Sensor A Circuit High Fuel Level Sensor Circuit Intermittent Vehicle Speed Sensor A Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Starter Request Circuit Incorrect Immobilizer Key Serial Communication Link Internal Control Module Random Access Memory (RAM) Error Reference <Ref. to EN(H4SO)(diag)-198, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-201, DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-203, DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-205, DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-207, DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-209, DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-211, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-214, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-217, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-219, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-221, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-221, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-221, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-222, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-222, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-223, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-225, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-227, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-16, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-228, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-229, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0447
P0448
P0451
P0452
P0453
P0456
P0457
P0458
P0459
P0461
P0462 P0463 P0464 P0500 P0506
P0507
P0512 P0513 P0600 P0604
EN(H4SO)(diag)-83

DTC P0605 Item Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (Mil Request) Park/Neutral Switch Input Circuit Low (AT Model) Neutral Switch Input Circuit Low (MT Model) Park/Neutral Switch Input Circuit High (AT Model) Neutral Switch Input Circuit High (MT Model) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Exhaust Gas Recirculation Flow Reference <Ref. to EN(H4SO)(diag)-230, DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-231, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-232, DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-232, DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-233, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-235, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-237, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-239, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-241, DTC P1152 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-243, DTC P1153 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-244, DTC P1160 RETURN SPRING FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-245, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-247, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-249, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-251, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-253, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-253, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-253, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-253, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0607
P0638
P0700
P0851
P0851
P0852
P0852
P1152
P1153
P1160 P1400
P1420
Fuel Tank Pressure Control Sol. Valve Circuit High Vent Control Solenoid Valve Function Problem Positive Crankcase Ventilation (Blowby) Function Problem EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input)
P1443
P1491
P1492
P1493
P1494
P1495
EN(H4SO)(diag)-84

DTC P1496 Item EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input) Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure Reference <Ref. to EN(H4SO)(diag)-253, DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-253, DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-254, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-257, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-259, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-17, DTC P1570 ANTENNA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-19, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-20, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-23, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-23, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-24, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-24, DTC P1578 METER FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-261, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-269, DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-270, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-276, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-281, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-283, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-284, DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-285, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-287, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1497
P1498
P1499
P1560 P1570 P1571 P1572
P1574 P1576 P1577 P1578 P1602 P2096
Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Control Module Programming Error Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle/Pedal Position Sensor A Minimum Stop Performance Throttle/Pedal Position Sensor/Switch D Circuit Low Input Throttle/Pedal Position Sensor/Switch D Circuit High Input
P2097
P2101
P2102
P2103
P2109
P2122
P2123
EN(H4SO)(diag)-85

DTC P2127 Item Throttle/Pedal Position Sensor/Switch E Circuit Low Input Throttle/Pedal Position Sensor/Switch E Circuit High Input Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation Reference <Ref. to EN(H4SO)(diag)-289, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO)(diag)-291, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2128
P2135
P2138
P2227
P2228 P2229
<Ref. to EN(H4SO)(diag)-293, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/Switch <Ref. to EN(H4SO)(diag)-296, DTC P2138 THROTTLE/PEDAL POSITION D/E Voltage Correlation SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Atmospheric Pressure Sensor Range/ <Ref. to EN(H4SO)(diag)-298, DTC P2227 BAROMETRIC PRESSURE CIRPerformance CUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Barometric Pressure Circuit Low <Ref. to EN(H4SO)(diag)-298, DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Barometric Pressure Circuit High <Ref. to EN(H4SO)(diag)-299, DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-86
Diagnostic Procedure with Diagnostic Trouble Code (DTC)

20.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B21
B134 ECM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
31
B134 1 2 8 9 10 18 19 20 28 29 30 B21 E2 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
21 1
E71
EN-04025
EN(H4SO)(diag)-87

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and variable valve lift diagnosis oil pressure switch. 4) Measure the resistance of harness between ECM and variable valve lift diagnosis oil pressure switch connector. Connector & terminal (B134) No. 31 (E71) No. 1: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. Measure the resistance between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E71) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Turn the ignition switch to ON. 2) Measure the voltage between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E71) No. 1 (+) Engine ground (): CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> Is the resistance 1 M: or more? Go to step 3. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and variable valve lift diagnosis oil pressure switch connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and variable valve lift diagnosis oil pressure switch connector.
Repair the short Go to step 4. circuit of harness to power supply between ECM and variable valve lift diagnosis oil pressure switch connector. Replace the oil End. switching solenoid valve. <Ref. to ME(H4SO)-89, Oil Switching Solenoid Valve.> Go to step 5. Check for oil routing. End.
Is DTC displayed?
Is DTC displayed?
EN(H4SO)(diag)-88

B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-10, DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134 ECM
32
B134
1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
22
1
B21 E2
E72
VVL DIAGNOSIS OIL PRESSURE SWITCH LH
EN-04026
EN(H4SO)(diag)-89

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and variable valve lift diagnosis oil pressure switch. 4) Measure the resistance of harness between ECM and variable valve lift diagnosis oil pressure switch connector. Connector & terminal (B134) No. 32 (E72) No. 1: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. Measure the resistance between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E72) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Turn the ignition switch to ON. 2) Measure the voltage between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E72) No. 1 (+) Engine ground (): CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> Is the resistance 1 M: or more? Go to step 3. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and variable valve lift diagnosis oil pressure switch connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and variable valve lift diagnosis oil pressure switch connector.
Repair the short Go to step 4. circuit of harness to power supply between ECM and variable valve lift diagnosis oil pressure switch connector. Replace the oil End. switching solenoid valve. <Ref. to ME(H4SO)-89, Oil Switching Solenoid Valve.> Go to step 5. Check for oil routing. End.
Is DTC displayed?
Is DTC displayed?
EN(H4SO)(diag)-90

C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-11, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
A/F, OXYGEN SENSOR RELAY SBF-5 6 4 5 3 2 1 B327 4 3 1 FRONT OXYGEN (A/F) SENSOR E22 B21 50 E2 6 E22 BATTERY B327 1 3 5 2 4 6
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
C2 C3 B8 B9 B1 B138 A: B134 B: B135 ECM C: B136 D: B137 A5 D1 D2 D3 D7
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-91

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 2 (E22) No. 4: (B136) No. 3 (E22) No. 4: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 9 (E22) No. 1: (B135) No. 8 (E22) No. 3: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 4. Replace the front oxygen (A/F) sensor. <Ref. to FU(H4SO)-35, Front Oxygen (A/F) Sensor.> Repair the poor Replace the front contact in ECM or oxygen (A/F) senfront oxygen (A/F) sor. <Ref. to sensor connector. FU(H4SO)-35, Front Oxygen (A/F) Sensor.>
CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 6 No. 4:
Is the resistance between 2 3 :?
CHECK POOR CONTACT. Is there poor contact in ECM or Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con(A/F) sensor connector. nector?
EN(H4SO)(diag)-92

D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-13, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-93

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E22) No. 6 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. Or replace the main relay. NOTE: In this case, repair the following item: Open circuit in harness between A/F, oxygen sensor relay connector and front oxygen (A/F) sensor connector Poor contact of A/F, oxygen sensor relay connector Poor contact of coupling connector Malfunction of A/ F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Replace the front oxygen (A/F) sensor. <Ref. to FU(H4SO)-35, Front Oxygen (A/F) Sensor.>
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 3. FRONT OXYGEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 2 (E22) No. 4: (B136) No. 3 (E22) No. 4:
CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground:
Is the resistance between 2 Repair the poor 3 :? contact of ECM connector.
EN(H4SO)(diag)-94

E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-15, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-95

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 2 (+) Chassis ground (): (B136) No. 3 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and front oxygen (A/F) sensor connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector
EN(H4SO)(diag)-96

F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-17, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
A/F, OXYGEN SENSOR RELAY SBF-5 6 4 5 3 2 1 B327 4 1 3 REAR OXYGEN SENSOR E23 B21 50 E2 2 E23 BATTERY B327 1 3 5 2 4 6 B138 1 2 3 4 5 6 7 8
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
A29 C4 B4 B1 B138 A: B134 B: B135 ECM C: B136 D: B137 A5 D1 D2 D3 D7
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-97

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (E23) No. 2 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. Or replace the main relay. NOTE: In this case, repair the following item: Open circuit in harness between A/F, oxygen sensor relay connector and rear oxygen sensor connector Poor contact of A/F, oxygen sensor relay connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Replace the rear oxygen sensor. <Ref. to FU(H4SO)-37, Rear Oxygen Sensor.>
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between the ECM and oxygen sensor connector. Connector & terminal (B136) No. 4 (E23) No. 1:
CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor connector terminals. Terminals No. 2 No. 1:
EN(H4SO)(diag)-98

G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-19, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-99

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 4 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and rear oxygen sensor connector. Repair the poor contact of ECM connector. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector
EN(H4SO)(diag)-100

H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-21, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MANIFOLD ABSOLUTE PRESSURE SENSOR E21
1 2 3
2 1 3
E21
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 E2 19 7 20 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
29 6 19 ECM
EN-04029
EN(H4SO)(diag)-101

Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK MANIFOLD ABSOLUTE PRESSURE Is the measured value 73.3 Go to step 3. SENSOR. 106.6 kPa (550 800 mmHg, 1) Start the engine and warm up engine until 21.65 31.50 inHg) when the coolant temperature is higher than 75C ignition is turned ON, and 20.0 (167F). 46.7 kPa (150 350 mmHg, 2) For AT models, set the select lever to P 5.91 13.78 inHg) during range or N range, and for MT models, place idling? the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the General Scan Tool Instruction Manual. CHECK THROTTLE OPENING ANGLE. Is the measured value less than Go to step 4. Read the data of throttle position signal using 5% when throttle is fully Subaru Select Monitor or general scan tool. closed? NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the General Scan Tool Instruction Manual. CHECK THROTTLE OPENING ANGLE. Is the measured value 85% or Replace the manimore when throttle is fully fold absolute presopen? sure sensor. <Ref. to FU(H4SO)-27, Manifold Absolute Pressure Sensor.> Step CHECK AIR INTAKE SYSTEM. No Go to step 2.
Replace the manifold absolute pressure sensor. <Ref. to FU(H4SO)-27, Manifold Absolute Pressure Sensor.>
Replace the electronic throttle control. <Ref. to FU(H4SO)-12, Throttle Body.>
EN(H4SO)(diag)-102

I:
DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-23, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
25
24
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
23
24
B21 E2
E67 1 2
E67 1 2
OIL SWITCHING SOLENOID VALVE RH
EN-05704
EN(H4SO)(diag)-103

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the resistance of harness between ECM and oil switching solenoid valve. Connector & terminal (B137) No. 25 (E67) No. 1: (B137) No. 24 (E67) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and oil switching solenoid valve connector. Replace the oil switching solenoid valve. <Ref. to ME(H4SO)-89, Oil Switching Solenoid Valve.>
CHECK HARNESS BETWEEN ECM AND OIL SWITCHING SOLENOID VALVE. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 25 Chassis ground: (B137) No. 24 Chassis ground: CHECK OIL SWITCHING SOLENOID VALVE. Measure the resistance between oil switching solenoid valve terminals. Terminals No. 1 No. 2:
Go to step 3.
Is the resistance between 6 Repair the poor 12 :? contact of ECM and oil switching solenoid valve connector.
EN(H4SO)(diag)-104

J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-24, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
25
24
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
23
24
B21 E2
E67 1 2
E67 1 2
EN-05704
EN(H4SO)(diag)-105

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 25 (+) Chassis ground (): (B137) No. 24 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 3. SWITCHING SOLENOID VALVE. Measure the resistance of harness between ECM and oil switching solenoid valve connector. Connector & terminal (B137) No. 25 (E67) No. 1: (B137) No. 24 (E67) No. 2: No Repair the short circuit of harness to power supply between ECM and oil switching solenoid valve connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Replace the oil CHECK OIL SWITCHING SOLENOID VALVE. Is the resistance between 6 Repair the poor switching solenoid contact of ECM Measure the resistance between oil switching 12 :? valve. <Ref. to and oil switching solenoid valve terminals. solenoid valve con- ME(H4SO)-89, Oil Terminals Switching Solenoid nector. No. 1 No. 2: Valve.>
EN(H4SO)(diag)-106

K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-25, DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
31
30
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
27
28
B21 E2
E68 1 2
E68 1 2
OIL SWITCHING SOLENOID VALVE LH
EN-05705
EN(H4SO)(diag)-107

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the resistance between ECM and oil switching solenoid valve. Connector & terminal (B137) No. 31 (E68) No. 1: (B137) No. 30 (E68) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and oil switching solenoid valve connector. Replace the oil switching solenoid valve. <Ref. to ME(H4SO)-89, Oil Switching Solenoid Valve.>
Go to step 3.
EN(H4SO)(diag)-108

L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-25, DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
31
30
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
27
28
B21 E2
E68 1 2
E68 1 2
EN-05705
EN(H4SO)(diag)-109

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 31 (+) Chassis ground (): (B137) No. 30 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 3. SWITCHING SOLENOID VALVE. Measure the resistance between ECM and oil switching solenoid valve connector. Connector & terminal (B137) No. 31 (E68) No. 1: (B137) No. 30 (E68) No. 2: No Repair the short circuit of harness to power supply between ECM and oil switching solenoid valve connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Replace the oil CHECK OIL SWITCHING SOLENOID VALVE. Is the resistance between 6 Repair the poor switching solenoid contact of ECM Measure the resistance between oil switching 12 :? valve. <Ref. to and oil switching solenoid valve terminals. solenoid valve con- ME(H4SO)-89, Oil Terminals Switching Solenoid nector. No. 1 No. 2: Valve.>
EN(H4SO)(diag)-110

M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-26, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 6 4 2 1 B47 MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR B3 3 BATTERY SBF-7
1
ECM
* *
B83
35
30
26
B135
18
34
B3
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-06837
EN(H4SO)(diag)-111

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> No Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
EN(H4SO)(diag)-112

N: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-28, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1
ECM
* *
B83
35
30
26
B135
18
34
B3
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-06837
EN(H4SO)(diag)-113

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF MASS AIR Is the voltage 10 V or more? FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the mass air flow and intake air temperature sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 3 (+) Engine ground (): Go to step 3. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and mass air flow and intake air temperature sensor connector Poor contact of main relay connector Repair the open circuit of harness between ECM and mass air flow and intake air temperature sensor connector.
CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and mass air flow and intake air temperature sensor connectors. Connector & terminal (B135) No. 26 (B3) No. 5: CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 26 Chassis ground: CHECK POOR CONTACT. Check for any poor contact in the ECM or the mass air flow or intake air temperature sensor connector.
Is there poor contact in the ECM or the mass air flow and intake air temperature sensor connector?
Repair the ground short circuit of harness between the ECM and the mass air flow and intake air temperature sensor connectors. Repair any poor Replace the mass contact in the ECM air flow and intake or the mass air flow air temperature and intake air tem- sensor. <Ref. to perature sensor FU(H4SO)-28, Mass Air Flow and connector. Intake Air Temperature Sensor.>
Go to step 5.
EN(H4SO)(diag)-114

O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-29, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1
ECM
* *
B83
35
30
26
B135
18
34
B3
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-06837
EN(H4SO)(diag)-115

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the mass air flow and intake air temperature sensor. 3) Start the engine. 4) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 4 Engine ground: Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair the short circuit to power in the harness between the ECM and the mass air flow and intake air temperature sensor connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and the mass air flow and intake air temperature sensor connector. Poor contact in ECM connector CHECK POOR CONTACT. Is there poor contact in the Repair any poor Replace the mass Check for any poor contact in the mass air flow mass air flow and intake air contact of the air flow and intake and intake air temperature sensor connector. temperature sensor connector? mass air flow and air temperature intake air temperasensor. <Ref. to ture sensor conFU(H4SO)-28, nector. Mass Air Flow and Intake Air Temperature Sensor.>
Go to step 4.
EN(H4SO)(diag)-116

P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-30, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3
2 1 3
E21
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 E2 19 7 20 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
29 6 19 ECM
EN-04029
EN(H4SO)(diag)-117

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Start the engine. 13.3 kPa (100 mmHg, 3.94 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF MANIFOLD Is the voltage 4.5 V or more? Go to step 3. ABSOLUTE PRESSURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) Engine ground (): No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact in ECM connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact of coupling connector Repair ground short circuit of harness between ECM and manifold absolute pressure sensor connector. Replace the manifold absolute pressure sensor. <Ref. to FU(H4SO)-27, Manifold Absolute Pressure Sensor.>
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and manifold absolute pressure sensor connector. Connector & terminal (B134) No. 6 (E21) No. 1:
CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 6 Chassis ground: CHECK POOR CONTACT. Check for poor contact in ECM and manifold absolute pressure sensor connector.
Go to step 5.
Is there poor contact in ECM or Repair the poor manifold absolute pressure contact in ECM or sensor connector? manifold absolute pressure sensor connector.
EN(H4SO)(diag)-118

Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-31, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3
2 1 3
E21
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 E2 19 7 20 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
29 6 19 ECM
EN-04029
EN(H4SO)(diag)-119

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Start the engine. 4) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 2 Engine ground: Check Yes Is the measured value 119.5 kPa Go to step 2. (896.5 mmHg, 35.29 inHg) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is the measured value 119.5 kPa Repair the short (896.5 mmHg, 35.29 inHg) or circuit to power in more? harness between ECM and manifold absolute pressure sensor connector.
CHECK POOR CONTACT. Check for poor contact in manifold absolute pressure sensor connector.
Is there poor contact in manifold absolute pressure sensor connector?
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact in ECM connector Poor contact of coupling connector Replace the maniRepair the poor fold absolute prescontact of manifold absolute pressure sensor. <Ref. to FU(H4SO)-27, sure sensor connector. Manifold Absolute Pressure Sensor.>
EN(H4SO)(diag)-120

R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-32, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1
ECM
* *
B83
35
30
26
B135
18
34
B3
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-06837
EN(H4SO)(diag)-121

Step Check CHECK ENGINE COOLANT TEMPERAIs the engine coolant temperaTURE. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Measure the engine coolant temperature using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Yes Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.> No Check DTC P0125 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-122

S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-34, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1
ECM
* *
B83
35
30
26
B135
18
34
B3
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-06837
EN(H4SO)(diag)-123

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and mass air flow and intake air temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 18 Chassis ground: Check Is the intake air temperature 120C (248F) or higher? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the ground short circuit of harness between the ECM and the mass air flow and intake air temperature sensor connectors.
Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
EN(H4SO)(diag)-124

T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-35, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1
ECM
* *
B83
35
30
26
B135
18
34
B3
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-06837
EN(H4SO)(diag)-125

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact in the ECM or the mass air flow and intake air temperature sensor connector. Check Is the intake air temperature less than 40C (40F) ? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair any poor contact in the ECM or the mass air flow and intake air temperature sensor connector. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the harness MASS AIR FLOW AND INTAKE AIR TEMand connector. PERATURE SENSOR CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connector from ECM and the following item: mass air flow and intake air temperature sensor. Open circuit of 3) Measure the resistance of harness between harness between ECM and mass air flow and intake air temperaECM and the mass ture sensor connectors. air flow and intake Connector & terminal air temperature (B135) No. 18 (B3) No. 1: sensor connector. (B135) No. 30 (B3) No. 2: Poor contact in joint connector CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? Repair the short Replace the mass MASS AIR FLOW AND INTAKE AIR TEMcircuit to power in air flow and intake PERATURE SENSOR CONNECTOR. the harness air temperature 1) Connect all connectors. between the ECM sensor. <Ref. to 2) Turn the ignition switch to ON. and the mass air FU(H4SO)-28, 3) Measure the voltage between ECM and flow and intake air Mass Air Flow and chassis ground. temperature sen- Intake Air TemperConnector & terminal sor connector. ature Sensor.> (B135) No. 18 (+) Chassis ground ():
EN(H4SO)(diag)-126

U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-36, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
ENGINE COOLANT TEMPERATURE SENSOR
E8
1 2
2 1
E8 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 8 19 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
34 29 ECM
EN-04033
EN(H4SO)(diag)-127

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 34 Chassis ground: Check Yes Is the engine coolant tempera- Go to step 2. ture 150C (302F) or higher? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Replace the Repair short cirengine coolant cuit in harness to temperature sen- ground between sor. <Ref. to ECM and engine FU(H4SO)-22, coolant temperaEngine Coolant ture sensor conTemperature Sen- nector. sor.>
EN(H4SO)(diag)-128

V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-37, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E8
1 2
2 1
E8 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 8 19 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
34 29 ECM
EN-04033
EN(H4SO)(diag)-129

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact in ECM and engine coolant temperature sensor connector. Check Yes Is the engine coolant tempera- Go to step 2. ture less than 40C (40F) ? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is there poor contact in ECM or Repair the poor engine coolant temperature contact in ECM or engine coolant sensor connector? temperature sensor connector. CHECK HARNESS BETWEEN ECM AND EN- Is the resistance less than 1 :? Go to step 4. Repair the harness GINE COOLANT TEMPERATURE SENSOR and connector. CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM and the following item: engine coolant temperature sensor. Open circuit in 3) Measure the resistance of harness between harness between ECM and engine coolant temperature sensor ECM and engine connector. coolant temperaConnector & terminal ture sensor con(B134) No. 34 (E8) No. 2: nector (B134) No. 29 (E8) No. 1: Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND EN- Is the voltage 5 V or more? Repair the short Replace the GINE COOLANT TEMPERATURE SENSOR circuit to power in engine coolant CONNECTOR. harness between temperature sen1) Connect all connectors. ECM and engine sor. <Ref. to 2) Turn the ignition switch to ON. coolant tempera- FU(H4SO)-22, 3) Measure the voltage between ECM and ture sensor conEngine Coolant chassis ground. nector. Temperature SenConnector & terminal sor.> (B134) No. 34 (+) Chassis ground ():
EN(H4SO)(diag)-130

W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-38, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY ELECTRONIC THROTTLE CONTROL RELAY 8 5 6 7 C21 C1 SBF-7 B362
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
ELECTRONIC THROTTLE CONTROL
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-131

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).>
EN(H4SO)(diag)-132

X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-39, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-133

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 (E57) No. 6: (B134) No. 29 (E57) No. 3: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 4.
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? Go to step 3. ELECTRONIC THROTTLE CONTROL. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 Engine ground:
CHECK HARNESS BETWEEN ECM AND Is the voltage 4.85 V or more? ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 (B134) No. 18:
Repair the short circuit to power in the harness between ECM and electronic throttle control connector. Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4SO)-12, Throttle Body.>
Repair the short circuit to power in the harness between ECM and electronic throttle control connector.
EN(H4SO)(diag)-134

Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-40, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine does not return to idle. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 Step CHECK TIRE SIZE. Check Yes Is the tire size as specified and Go to step 2. the same size as three other wheels? Is the engine coolant normal? Go to step 3. No Replace the tire.
CHECK ENGINE COOLANT. Check the following items: Amount of engine coolant Engine coolant freeze Contamination of engine coolant CHECK THERMOSTAT.
Does the thermostat remain opened?
Replace the thermostat. <Ref. to CO(H4SO)-17, Thermostat.>
Fill or replace the engine coolant. <Ref. to CO(H4SO)-13, REPLACEMENT, Engine Coolant.> Replace the engine coolant temperature sensor. <Ref. to FU(H4SO)-22, Engine Coolant Temperature Sensor.>
EN(H4SO)(diag)-135

Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-42, DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E8
1 2
2 1
E8 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 8 19 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
34 29 ECM
EN-04033
EN(H4SO)(diag)-136

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure the resistance between engine coolant temperature sensor terminals when the engine coolant is cold and after warmed up. Terminals No. 1 No. 2: Check Yes Is the resistance of engine cool- Repair the poor ant temperature sensor differ- contact of ECM ent between when engine connector. coolant is cold and after warmed up? No Replace the engine coolant temperature sensor. <Ref. to FU(H4SO)-22, Engine Coolant Temperature Sensor.>
EN(H4SO)(diag)-137

AA:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-44, DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Thermostat remains open. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 Step CHECK ENGINE COOLANT. Check Are the coolant level and mixture ratio of engine coolant to anti-freeze solution correct? Yes Go to step 2. No Replace the engine coolant. <Ref. to CO(H4SO)-13, REPLACEMENT, Engine Coolant.> Repair radiator fan Replace the thercircuit. <Ref. to mostat. <Ref. to CO(H4SO)-24, CO(H4SO)-17, Radiator Main Fan Thermostat.> and Fan Motor.> and <Ref. to CO(H4SO)-26, Radiator Sub Fan and Fan Motor.>
CHECK RADIATOR FAN. 1) Start the engine. 2) Check the radiator fan operation.
Does the radiator fan continuously rotate for 3 minutes or more during idling?
EN(H4SO)(diag)-138

AB:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-46, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-139

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 9 Chassis ground: (B135) No. 8 Chassis ground: CHECK POOR CONTACT. Check for poor contact in the front oxygen (A/F) sensor connector. Check Yes Has water entered the connec- Completely tor? remove any water inside. Is the resistance 1 M: or Go to step 3. more? No Go to step 2.
Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.
Is there poor contact in front oxygen (A/F) sensor connector?
Repair the poor contact of the front oxygen (A/F) sensor connector.
Replace the front oxygen (A/F) sensor. <Ref. to FU(H4SO)-35, Front Oxygen (A/F) Sensor.>
EN(H4SO)(diag)-140

AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-48, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-141

Step Check CHECK FRONT OXYGEN (A/F) SENSOR Has water entered the connecCONNECTOR AND COUPLING CONNECtor? TOR. CHECK HARNESS BETWEEN ECM AND Is the voltage 8 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 9 (+) Chassis ground (): (B135) No. 8 (+) Chassis ground (): Yes Completely remove any water inside. Repair the short circuit to power in the harness between ECM and front oxygen (A/F) sensor connector. No Go to step 2.
Replace the front oxygen (A/F) sensor. <Ref. to FU(H4SO)-35, Front Oxygen (A/F) Sensor.>
EN(H4SO)(diag)-142

AD:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-50, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-143

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a hole Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor. <Ref. to FU(H4SO)-35, Front Oxygen (A/F) Sensor.>
EN(H4SO)(diag)-144

AE:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-53, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-145

No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor. <Ref. to sensor connector. FU(H4SO)-35, Front Oxygen (A/F) Sensor.> Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 9 (E22) No. 1: (B135) No. 8 (E22) No. 3:
EN(H4SO)(diag)-146

AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-55, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-147

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E23) No. 3: (B134) No. 29 (E23) No. 4: No Go to step 2.
Go to step 3.
CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 0.5 V? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E23) No. 3 (+) Chassis ground ():
CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. Looseness and improper attachment of exhaust system parts Damage (crack, hole etc.) of parts Looseness and improper attachment of parts between front oxygen (A/F) sensor and rear oxygen sensor
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H4SO)-37, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Repair or replace Replace the rear faulty parts. oxygen sensor. <Ref. to FU(H4SO)-37, Rear Oxygen Sensor.>
EN(H4SO)(diag)-148

AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-57, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-149

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E23) No. 3: (B134) No. 29 (E23) No. 4: No Go to step 2.
Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H4SO)-37, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Repair or replace Replace the rear faulty parts. oxygen sensor. <Ref. to FU(H4SO)-37, Rear Oxygen Sensor.>
EN(H4SO)(diag)-150

AH:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-58, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-151

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E23) No. 3: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Is the resistance 1 M: or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 :? Replace the rear Even if DTC is oxygen sensor. detected, the cir<Ref. to cuit has returned to FU(H4SO)-37, a normal condition Rear Oxygen Sen- at this time. Reprosor.> duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (E23) No. 3 Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 No. 4
EN(H4SO)(diag)-152

AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-63, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-153

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E23) No. 3: (B134) No. 29 (E23) No. 4: Check Yes Is the voltage 490 mV or more? Go to step 6. No Go to step 2.
Is the voltage 250 mV or less? Go to step 6.
Go to step 3.
Has water entered the connec- Completely tor? remove any water inside. Is the resistance less than 1 :? Go to step 5.
Go to step 4.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector
EN(H4SO)(diag)-154

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 0.5 V? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E23) No. 3 (+) Chassis ground (): Yes Replace the rear oxygen sensor. <Ref. to FU(H4SO)-37, Rear Oxygen Sensor.> No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Replace the rear oxygen sensor. <Ref. to FU(H4SO)-37, Rear Oxygen Sensor.>
Repair or replace faulty parts.
AJ:DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO)(diag)-156, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-155

AK:DTC P0172 SYSTEM TOO RICH (BANK 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-67, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 2 Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 339.5 360.5 kPa (3.5 3.7 kg/cm2, WARNING: Place NO OPEN FLAMES signs near the 49 52 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. <Ref. to ME(H4SO)26, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant temperaSENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Step CHECK EXHAUST SYSTEM. Yes No Repair the exhaust Go to step 2. system. Repair the air Go to step 3. intake system. Go to step 4. Repair the following item. Fuel pressure is too high: Clogged fuel line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel line Replace the engine coolant temperature sensor. <Ref. to FU(H4SO)-22, Engine Coolant Temperature Sensor.>
Go to step 5.
EN(H4SO)(diag)-156

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 70C (158F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the measured value 2.0 5.0 g/s (0.26 0.66 lb/m)? Yes Go to step 6. No Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
Subtract ambient temperature Repair the poor from intake air temperature. Is contact of ECM the obtained value 10 50C connector. (18 90F)?
Check the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
EN(H4SO)(diag)-157

AL:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-68, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
FUEL TEMPERATURE SENSOR
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
B135 ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B83
17 30
B97
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05707
EN(H4SO)(diag)-158

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> No Replace the fuel temperature sensor. <Ref. to EC(H4SO)-10, Fuel Temperature Sensor.>
EN(H4SO)(diag)-159

AM:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-71, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
B135 ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B83
17 30
B97
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05707
EN(H4SO)(diag)-160

Step Check CHECK CURRENT DATA. Is the temperature 120C 1) Start the engine. (248F) or higher? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the ground short circuit of harness between ECM and fuel pump.
CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or FUEL TEMPERATURE SENSOR CONNEC- more? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 17 Chassis ground:
Replace the fuel temperature sensor. <Ref. to EC(H4SO)-10, Fuel Temperature Sensor.>
EN(H4SO)(diag)-161

AN:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-72, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
B135 ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B83
17 30
B97
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05707
EN(H4SO)(diag)-162

Step Check CHECK CURRENT DATA. Is the temperature less than 1) Start the engine. 40C (40F)? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is there poor contact in the CHECK POOR CONTACT. Repair any poor contact between the ECM and ECM or fuel temperature sensor connectors? fuel temperature sensor connectors.
CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance of the harness between the ECM and fuel temperature sensor connector. Connector & terminal (B135) No. 17 (R58) No. 2: (B135) No. 30 (R58) No. 3:
Repair any poor contact between the ECM and fuel temperature sensor connectors. Is the resistance less than 1 :? Go to step 4.
CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 17 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and fuel temperature sensor connector Poor contact of coupling connector Poor contact in joint connector Repair the short Replace the fuel circuit to power in temperature senthe harness sor. <Ref. to between the ECM EC(H4SO)-10, and fuel tempera- Fuel Temperature ture sensor conSensor.> nector.
EN(H4SO)(diag)-163

AO:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-73, DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E75 OIL TEMPERATURE SENSOR
1 2
E75 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 19 6 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
23
B134 ECM
29
EN-04036
EN(H4SO)(diag)-164

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> No Replace the oil temperature sensor. <Ref. to FU(H4SO)-34, Oil Temperature Sensor.>
EN(H4SO)(diag)-165

AP:DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-75, DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2
E75 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 19 6 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
23
B134 ECM
29
EN-04036
EN(H4SO)(diag)-166

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND OIL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and oil temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 23 Chassis ground: Check Is the oil temperature 215C (419F) or more? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Replace the oil Repair the short temperature sen- circuit to ground in harness between sor. <Ref. to FU(H4SO)-34, Oil ECM and oil temTemperature Sen- perature sensor. sor.>
EN(H4SO)(diag)-167

AQ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-76, DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2
E75 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 19 6 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
23
B134 ECM
29
EN-04036
EN(H4SO)(diag)-168

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact of ECM and oil temperature sensor connector. Check Yes Is the oil temperature less than Go to step 2. 40C (40F)? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is there poor contact in ECM or Repair the poor oil temperature sensor connec- contact in ECM or oil temperature tor? sensor connector. CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 4. Repair the harness TEMPERATURE SENSOR CONNECTOR. and connector. 1) Turn the ignition switch to OFF. NOTE: 2) Disconnect the connector from ECM and oil In this case, repair temperature sensor. the following item: 3) Measure the resistance of harness between Open circuit in ECM and oil temperature sensor connector. harness between Connector & terminal ECM and oil tem(B134) No. 23 (E75) No. 2: perature sensor (B134) No. 29 (E75) No. 1: connector Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND OIL Is the voltage 5 V or more? Repair the short Replace the oil TEMPERATURE SENSOR CONNECTOR. circuit in harness temperature sen1) Connect all connectors. to power supply sor. <Ref. to 2) Turn the ignition switch to ON. between ECM and FU(H4SO)-34, Oil 3) Measure the voltage between ECM and oil temperature Temperature Senchassis ground. sensor connector. sor.> Connector & terminal (B134) No. 23 (+) Chassis ground ():
EN(H4SO)(diag)-169

AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-77, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-170

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).>
EN(H4SO)(diag)-171

AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-78, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-172

Repair the short circuit to power in the harness between ECM and electronic throttle control connector. Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4SO)-12, Throttle Body.>
AT:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO)(diag)-174, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AU:DTC P0302 CYLINDER 2 MISFIRE DETECTED

AV:DTC P0303 CYLINDER 3 MISFIRE DETECTED

EN(H4SO)(diag)-173

AW:DTC P0304 CYLINDER 4 MISFIRE DETECTED

DTC DETECTING CONDITION: Two consecutive driving cycles with fault Immediately at fault recognition (A misfire which could damage catalyst occurs.) GENERAL DESCRIPTION <Ref. to GD(H4SO)-85, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling Rough driving CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 6 4 2 1 B47
BATTERY SBF-7
B137
ECM
10
48
42
43
E5 2 1 2 1
E16 2 B21 1
FUEL INJECTOR No. 1
FUEL INJECTOR No. 2
FUEL INJECTOR No. 3
E5 E6 1 2
E16 E17
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
44
EN-06833
EN(H4SO)(diag)-174

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 Engine ground: #2 (E16) No. 1 Engine ground: #3 (E6) No. 1 Engine ground: #4 (E17) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. Measure the resistance of harness between ECM and fuel injector on faulty cylinders. Connector & terminal #1 (B137) No. 8 (E5) No. 1: #2 (B137) No. 9 (E16) No. 1: #3 (B137) No. 10 (E6) No. 1: #4 (B137) No. 11 (E17) No. 1: Check Is the voltage 10 V or more? Yes Go to step 6. No Go to step 2.
Go to step 3.
Repair the ground short circuit of harness between ECM and fuel injector.
CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector Replace the faulty fuel injector. <Ref. to FU(H4SO)-30, Fuel Injector.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the main relay connector and fuel injector connector on faulty cylinders Poor contact of coupling connector Poor contact of main relay connector
Repair the poor contact of all connectors in fuel injector circuit.
EN(H4SO)(diag)-175

Step CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK INSTALLATION CONDITION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. Check Is the voltage 10 V or more? Yes No Go to step 7. Repair the short circuit to power in harness between ECM and fuel injector connector.
Is the resistance less than 1 :? Replace the faulty Go to step 8. fuel injector. <Ref. to FU(H4SO)-30, Fuel Injector.>
10
11
12
Is the camshaft position sensor Tighten the cam- Go to step 9. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 10. CHECK CRANK SPROCKET. does it have broken teeth? sprocket. <Ref. to Remove the timing belt cover. <Ref. to ME(H4SO)-50, ME(H4SO)-43, REMOVAL, Timing Belt Cover.> Crank Sprocket.> CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 11. TIMING BELT. from its proper position? tion condition of Turn the crankshaft using ST, and align the timing belt. <Ref. to alignment mark on crank sprocket with alignME(H4SO)-44, ment mark on cylinder block. Timing Belt.> ST 499987500 CRANKSHAFT SOCKET CHECK FUEL LEVEL. Is the fuel meter indication Go to step 12. Refill the fuel so higher than the Lower level? that fuel meter indication is higher than the Lower level. After replenishing fuel, Go to step 12. CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 14. Go to step 13. CATOR LIGHT. light illuminate or blink? 1) Clear the memory using the Subaru Select Monitor or general scan tool. <Ref. to EN(H4SO)(diag)-50, Clear Memory Mode.> NOTE: SUBARU SELECT MONITOR <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool Refer to the general scan tool operation manual. 2) Start the engine, and drive the vehicle 10 minutes or more.
EN(H4SO)(diag)-176

Step CHECK CAUSE OF MISFIRE. Check Yes Was the cause of misfire identi- Finish diagnostics fied when the engine is runoperation, if the ning? engine has no abnormality. No Repair the poor contact of connector. NOTE: In this case, repair the following item: Poor contact of ignition coil connector Poor contact in fuel injector connector on faulty cylinders Poor contact in ECM connector Poor contact of coupling connector Go to step 15.
13
14
CHECK AIR INTAKE SYSTEM.
Is there any fault in air intake system?
15
16
17
18
19
CHECK MISFIRE SYMPTOM. 1) Turn the ignition switch to ON. 2) Read the DTC. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK DTC. Are DTC P0301 and P0302 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Are DTC P0303 and P0304 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Are DTC P0301 and P0303 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Are DTC P0302 and P0304 displayed on the Subaru Select Monitor or general scan tool?
Repair the air intake system. NOTE: Check the following items. Are there air leaks or air suction caused by loose or dislocated nuts and bolts? Are there cracks or any disconnection of hoses? Does the Subaru Select Moni- Go to step 20. Go to step 16. tor or general scan tool indicate only one DTC?
Go to step 21.
Go to step 17.
Go to step 22.
Go to step 18.
Go to step 23.
Go to step 19.
Go to step 24.
Go to step 25.
EN(H4SO)(diag)-177

Step ONLY ONE CYLINDER. Check Is there any fault in the cylinder? Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plug Spark plug cord Fuel injector Compression ratio Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Ignition coil Compression ratio If any fault are not found, check the IGNITION CONTROL SYSTEM of #1 and #2 cylinders side. <Ref. to EN(H4SO)(diag)71, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Ignition coil Compression ratio If any fault are not found, check the IGNITION CONTROL SYSTEM of #3 and #4 cylinders side. <Ref. to EN(H4SO)(diag)71, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> No Go to DTC P0171. <Ref. to EN(H4SO)(diag)155, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to DTC P0171. <Ref. to EN(H4SO)(diag)155, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
20
21
GROUP OF #1 AND #2 CYLINDERS.
Are there any faults in #1 and #2 cylinders?
22
Go to DTC P0171. <Ref. to EN(H4SO)(diag)155, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-178

Step GROUP OF #1 AND #3 CYLINDERS. Check Are there any faults in #1 and #3 cylinders? Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio Skipping timing belt teeth Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio Skipping timing belt teeth Go to DTC P0171. <Ref. to EN(H4SO)(diag)155, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> No Go to DTC P0171. <Ref. to EN(H4SO)(diag)155, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to DTC P0171. <Ref. to EN(H4SO)(diag)155, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio
23
24
25
CYLINDER AT RANDOM.
Is the engine idle rough?
EN(H4SO)(diag)-179

AX:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-86, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance Knocking occurs. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
KNOCK SENSOR E14 1 2 2 1 E14
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 19 16 B21 B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
29 25 15 B134
ECM
E
EN-04038
EN(H4SO)(diag)-180

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 15 (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor terminals. Terminals No. 1 No. 2: Check Is the resistance 600 k: or more? Yes Go to step 2. No Repair the poor contact of ECM connector.
Is the resistance 600 k: or more?
Replace the knock sensor. <Ref. to FU(H4SO)-25, Knock Sensor.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and knock sensor connector Poor contact of the knock sensor connector Poor contact of coupling connector
EN(H4SO)(diag)-181

AY:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-87, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance Knocking occurs. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 19 16 B21 B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
29 25 15 B134
ECM
E
EN-04038
EN(H4SO)(diag)-182

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 15 (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor terminals. Terminals No. 1 No. 2: Check Is the resistance less than 500 k:? Yes Go to step 2. No Go to step 3.
Is the resistance less than 500 k:?
CHECK INPUT SIGNAL OF ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 15 (+) Chassis ground ():
Repair the short circuit to ground in harness between ECM and knock sensor connector. NOTE: The harness between both connectors are shielded. Remove the shield and repair the short circuit of harness. Even if DTC is Repair the poor detected, the cir- contact of ECM cuit has returned to connector. a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
Replace the knock sensor. <Ref. to FU(H4SO)-25, Knock Sensor.>
EN(H4SO)(diag)-183

AZ:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-88, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
CRANKSHAFT POSITION SENSOR
E10 1 2
2 1
E10
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 15 14 B21
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
14 13 24
E
EN-04039
EN(H4SO)(diag)-184

Step CHECK INSTALLATION CONDITION OF CRANKSHAFT POSITION SENSOR. Check Is the crankshaft position sensor installation bolt tightened securely? Yes Go to step 2. No Tighten the crankshaft position sensor installation bolt securely. Replace the crankshaft position sensor. <Ref. to FU(H4SO)-23, Crankshaft Position Sensor.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and crankshaft position sensor connector Poor contact of coupling connector
CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 and 1) Turn the ignition switch to OFF. 4 k:? 2) Remove the crankshaft position sensor. 3) Measure the resistance between connector terminals of crankshaft position sensor. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? CRANK SHAFT POSITION SENSOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and crankshaft position sensor connector. Connector & terminal (B134) No. 13 (E10) No. 1: (B134) No. 14 (E10) No. 2:
Go to step 3.
Repair the poor contact of ECM and crankshaft position sensor connector.
EN(H4SO)(diag)-185

BA:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-90, DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E10 1 2
2 1
E10
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 15 14 B21
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
14 13 24
E
EN-04039
EN(H4SO)(diag)-186

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened Turn the ignition switch to OFF. securely? CHECK CRANK SPROCKET. Remove the timing belt cover. Are crank sprocket teeth cracked or damaged? Yes Go to step 2. No Tighten the crankshaft position sensor installation bolt securely. Replace the crank Go to step 3. sprocket. <Ref. to ME(H4SO)-50, Crank Sprocket.> Repair the installa- Replace the cranktion condition of shaft position sentiming belt. <Ref. to sor. <Ref. to ME(H4SO)-44, FU(H4SO)-23, Timing Belt.> Crankshaft Position Sensor.>
CHECK INSTALLATION CONDITION OF Is the timing belt dislocated TIMING BELT. from its proper position? Turn the crankshaft, and align alignment mark on crank sprocket with alignment mark on cylinder block.
EN(H4SO)(diag)-187

BB:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-92, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E15 1 2
2 1
E15
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 13 12 B21
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
22 12 24
E
EN-04040
EN(H4SO)(diag)-188

No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the ECM and camshaft position sensor connector Poor contact in ECM connector Poor contact of coupling connector Is the resistance 1 M: or Go to step 3. Repair the short CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR. more? circuit to ground in Measure the resistance between camshaft harness between position sensor connector and engine ground. ECM and camshaft position sensor. Connector & terminal (E15) No. 1 Engine ground: NOTE: The harness between both connectors are shielded. Remove the shield and repair the ground short circuit of the harness circuit. CHECK INSTALLATION CONDITION OF Is the camshaft position sensor Go to step 4. Tighten the camCAMSHAFT POSITION SENSOR. installation bolt tightened shaft position sensecurely? sor installation bolt securely. CHECK CAMSHAFT POSITION SENSOR. Replace the camIs the resistance between 1 and Repair the poor 1) Remove the camshaft position sensor. 4 k:? contact of ECM or shaft position sen2) Measure the resistance between connector camshaft position sor. <Ref. to terminals of camshaft position sensor. sensor connector. FU(H4SO)-24, Terminals Camshaft Position No. 1 No. 2: Sensor.> Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. CAMSHAFT POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and camshaft position sensor. 3) Measure the resistance of harness between ECM and camshaft position sensor connector. Connector & terminal (B134) No. 12 (E15) No. 1: (B134) No. 22 (E15) No. 2:
EN(H4SO)(diag)-189

BC:DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE (BANK 1 OR SINGLE SENSOR)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-94, DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E15 1 2
2 1
E15
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E2 13 12 B21
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
22 12 24
E
EN-04040
EN(H4SO)(diag)-190

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. CAMSHAFT POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and camshaft position sensor. 3) Measure the resistance of harness between ECM and camshaft position sensor connector. Connector & terminal (B134) No. 12 (E15) No. 1: (B134) No. 22 (E15) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the ECM and camshaft position sensor connector Poor contact in ECM connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and camshaft position sensor. NOTE: The harness between both connectors are shielded. Remove the shield and repair the ground short circuit of the harness circuit. Tighten the camshaft position sensor installation bolt securely. Replace the camshaft position sensor. <Ref. to FU(H4SO)-24, Camshaft Position Sensor.> Go to step 6.
Is the resistance 1 M: or CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR. more? Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 1 Engine ground:
Go to step 3.
CHECK INSTALLATION CONDITION OF CAMSHAFT POSITION SENSOR.
Is the camshaft position sensor Go to step 4. installation bolt tightened securely? Is the resistance between 1 and Go to step 5. 4 k:?
CHECK CAMSHAFT POSITION SENSOR. 1) Remove the camshaft position sensor. 2) Measure the resistance between connector terminals of camshaft position sensor. Terminals No. 1 No. 2: CHECK CAM SPROCKET. Remove the timing belt cover. <Ref. to ME(H4SO)-43, Timing Belt Cover.> CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align alignment mark on cam sprocket with alignment mark on timing belt cover LH. ST 499987500 CRANKSHAFT SOCKET
Are cam sprocket teeth cracked Replace the cam or damaged? sprocket. <Ref. to ME(H4SO)-49, Cam Sprocket.> Is the timing belt dislocated Repair the installafrom its proper position? tion condition of timing belt. <Ref. to ME(H4SO)-44, Timing Belt.>
Replace the camshaft position sensor. <Ref. to FU(H4SO)-24, Camshaft Position Sensor.>
EN(H4SO)(diag)-191

BD:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-96, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Movement performance problem when engine is low speed. Improper idling Movement performance problem CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY E18 5 3 6 4 2 1 48 B47 B47 B21 E2 1 3 5 2 4 6 BATTERY SBF-7 1 2 3 4 5 6
B21 5 2
EGR VALVE E18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 3 4 6
B134 1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
E2 26 25 29 30 B21 B134 ECM 9 8 10 20
EN-06839
EN(H4SO)(diag)-192

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK EGR VALVE. Remove the EGR valve. Check Yes No Is the measured value 53.3 kPa Make sure that the Go to step 2. (400 mmHg, 15.75 inHg) or EGR valve, manimore? fold absolute pressure sensor and throttle body are installed securely.
Are there holes, plugged piping Repair the EGR or foreign objects caught in the system. EGR system?
Replace the EGR valve. <Ref. to FU(H4SO)-29, EGR Valve.>
EN(H4SO)(diag)-193

BE:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-99, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-194

Step CHECK EXHAUST SYSTEM. Check for gas leaks or air suction caused by loose or dislocated nuts and bolts, and open hole at exhaust pipes. NOTE: Check the following positions. Between cylinder head and front exhaust pipe Between front exhaust pipe and front catalytic converter Between front catalytic converter and rear catalytic converter Looseness and improper attachment of front oxygen (A/F) sensor or rear oxygen sensor CHECK WAVEFORM DATA ON THE SUBARU SELECT MONITOR (WHILE DRIVING). 1) Drive at a constant speed between 80 112 km/h (50 70 MPH). 2) After 5 minutes have elapsed in the condition of step 1), use the Subaru Select Monitor while still driving to read the waveform data. At normal condition
1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1 0.5 10 sec/div
Check Is there any fault in exhaust system?
Yes No Repair or replace Go to step 2. the exhaust system. <Ref. to EX(H4SO)-2, General Description.>
Is normal waveform pattern dis- Even if DTC is Go to step 3. played? detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
EN-06666
At abnormal condition (numerous inversion)

1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1
0.5 10 sec/div
EN-06667
EN(H4SO)(diag)-195

Step Check Yes CHECK WAVEFORM DATA ON THE SUBA- Is normal waveform pattern dis- Go to step 4. RU SELECT MONITOR (WHILE IDLING). played? 1) Run the engine at idle. 2) In the condition of step 1), use the Subaru Select Monitor to read the waveform data. At normal condition
1
No The waveform is displayed at abnormal condition 1:Go to step 4. The waveform is displayed at abnormal condition 2:Go to step 5.
REAR OXYGEN SENSOR VOLTAGE (V)
0 10 sec/div
EN-06668
At abnormal condition 1 (numerous inversion)

1
0 10 sec/div
EN-06669
At abnormal condition 2 (noise input)

1
0 10 sec/div
EN-06670
Is the catalytic converter dam- Replace the cataaged? lytic converter. <Ref. to EC(H4SO)-3, Front Catalytic Converter.> CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside.
CHECK CATALYTIC CONVERTER.
Go to step 5.
Go to step 6.
EN(H4SO)(diag)-196

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 7. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E23) No. 3: (B134) No. 29 (E23) No. 4: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: Repair the following locations. Open circuit in harness between ECM and rear oxygen sensor connector Poor contact in ECM and rear oxygen sensor Poor contact in ECM connector Repair the open circuit in the rear oxygen sensor harness.
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E23) No. 3 (+) Chassis ground ():
Is the voltage 0.2 0.5 V?
Go to step 8.
CHECK REAR OXYGEN SENSOR SHIELD. Is the resistance less than 1 :? 1) Turn the ignition switch to OFF. 2) Expose the rear oxygen sensor connector body side harness sensor shield. 3) Measure the resistance between the sensor shield and chassis ground.
Replace the rear oxygen sensor. <Ref. to FU(H4SO)-37, Rear Oxygen Sensor.>
EN(H4SO)(diag)-197

BF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-101, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3 SBF-7 6 4 2 1 B47 C: B136 D: B137
BATTERY
ECM
C17
C28
14
15
41
R1
48 2
B97
D29
B21 E2
7 R46 6
R15 1 5 R213 R68 1 2 1
R67
R144 1 2
E4
DRAIN VALVE
PRESSURE CONTROL SOLENOID VALVE C: B136 5 6 14 15 16 25 26 27 33 34 35 D:
PURGE CONTROL SOLENOID VALVE B137 R213 1 2 3 4 5 6 7 8
B21
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R68 1 2
R144 1 2
E4 1 2
R67 1 2 3 4 5 6
EN-06840
EN(H4SO)(diag)-198

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine? Yes Go to step 2. No Tighten fuel filler cap securely.
Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H4SO)-52, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H4SO)-16, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: The drain valve can be operated using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H4SO)-7, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)51, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H4SO)-13, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 1.0 mm (0.04 in) dia. on evapo- the evaporation 1) Turn the ignition switch to OFF. ration line? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H4SO)-65, tor. Fuel Delivery and Evaporation Lines.>
CHECK FUEL FILLER PIPE GASKET.
Replace with a genuine fuel filler cap. Go to step 4.
EN(H4SO)(diag)-199

Step CHECK CANISTER. Check Is the canister damaged or is there a hole of more than 1.0 mm (0.04 in) dia. in it? Is the fuel tank damaged or is there any hole of more than 1.0 mm (0.04 in) dia. in it? Is there any hole of more than 1.0 mm (0.04 in) dia., crack, clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system? Yes Repair or replace the canister. <Ref. to EC(H4SO)-5, Canister.> Repair or replace the fuel tank. <Ref. to FU(H4SO)-45, Fuel Tank.> Repair or replace the hoses or pipes. No Go to step 9.
CHECK FUEL TANK. Remove the fuel tank. <Ref. to FU(H4SO)-45, Fuel Tank.> CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.
Go to step 10.
10
EN(H4SO)(diag)-200

BG:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-117, DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3
BATTERY
SBF-7
6 4 2 1 B47
R46 7 14 B97 R1 R15 6 1
R67 1 2 R213 R144

DRAIN VALVE
17 B136 ECM
B47 1 3 5 2 4 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
R67 1 2 3 4 5 6
R213 1 2 3 4 5 6 7 8
R144 1 2
EN-06841
EN(H4SO)(diag)-201

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 17 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Measure the resistance between the drain valve connector and chassis ground. Connector & terminal (R144) No. 2 Chassis ground: CHECK HARNESS BETWEEN ECM AND DRAIN VALVE. Measure the resistance of harness between ECM and drain valve connector. Connector & terminal (B136) No. 17 (R144) No. 2: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair the ground short circuit of harness between ECM and drain valve connector.
CHECK DRAIN VALVE. Is the resistance between 10 Measure the resistance between drain valve 100 :? terminals. Terminals No. 1 No. 2: CHECK POWER SUPPLY TO DRAIN VALVE. Is the voltage 10 V or more? 1) Turn the ignition switch to ON. 2) Measure the voltage between drain valve and chassis ground. Connector & terminal (R144) No. 1 (+) Chassis ground ():
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and drain valve connector Poor contact of coupling connector Replace the drain valve. <Ref. to EC(H4SO)-16, Drain Valve.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay connector and drain valve connector Poor contact of coupling connector Poor contact of main relay connector
Repair poor contact of the drain valve connector.
EN(H4SO)(diag)-202

BH:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-119, DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3
BATTERY
SBF-7
6 4 2 1 B47
R46 7 14 B97 R1 R15 6 1
R67 1 2 R213 R144

DRAIN VALVE
17 B136 ECM
B47 1 3 5 2 4 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
R67 1 2 3 4 5 6
R213 1 2 3 4 5 6 7 8
R144 1 2
EN-06841
EN(H4SO)(diag)-203

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 17 (+) Chassis ground (): CHECK DRAIN VALVE. Is the resistance less than 1 :? 1) Turn the ignition switch to OFF. 2) Measure the resistance between drain valve terminals. Terminals No. 1 No. 2: Yes No Repair the short Go to step 2. circuit to the power supply in the harness between the ECM and drain valve connector.
Replace the drain valve. <Ref. to EC(H4SO)-16, Drain Valve.>
EN(H4SO)(diag)-204

BI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-121, DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
FUEL TANK PRESSURE SENSOR
1 R47 R213 4 R15 R1 13 B97
7 6
17
* *
B83
*
22 32 30
B135 ECM
B83 1 2 3 4 5 6 7 8
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
R47 1 2 3
R213 1 2 3 4 5 6 7 8
EN-05047
EN(H4SO)(diag)-205

Step CHECK FUEL FILLER CAP. 1) Turn the ignition switch to OFF. 2) Open the fuel flap. CHECK PRESSURE VACUUM LINE. NOTE: Check the following items. Disconnection, leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank Disconnection, leakage and clogging of the air ventilation hoses and pipes between fuel filler pipe and fuel tank Check Is the fuel filler cap tightened securely? Is there any fault in pressure/ vacuum line? Yes Go to step 2. No Tighten fuel filler cap securely. Replace the fuel tank pressure sensor. <Ref. to EC(H4SO)-12, Fuel Tank Pressure Sensor.>
Repair or replace the hoses and pipes.
EN(H4SO)(diag)-206

BJ:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-123, DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* *
B83
*
22 32 30
B135 ECM
B83 1 2 3 4 5 6 7 8
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
R47 1 2 3
R213 1 2 3 4 5 6 7 8
EN-05047
EN(H4SO)(diag)-207

Step CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK FUEL TANK PRESSURE SENSOR POWER SOURCE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the fuel tank pressure sensor connector and chassis ground. Connector & terminal (R47) No. 3 (+) Chassis ground (): Check Yes Is the measured value less than Go to step 2. 7.41 kPa (55.6 mmHg, 2.19 inHg)? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact in ECM connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel tank pressure sensor connector. Replace the fuel tank pressure sensor. <Ref. to EC(H4SO)-12, Fuel Tank Pressure Sensor.>
Is the voltage 4.5 V or more?
Go to step 3.
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between the ECM and fuel tank pressure sensor connector. Connector & terminal (B135) No. 32 (R47) No. 2:
CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 32 Chassis ground: CHECK POOR CONTACT. Check for poor contact between the ECM and fuel tank pressure sensor connector.
Go to step 5.
Is there poor contact in the Repair the poor ECM or fuel tank pressure sen- contact in the ECM sor connector? or fuel tank pressure sensor connector.
EN(H4SO)(diag)-208

BK:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-125, DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* *
B83
*
22 32 30
B135 ECM
B83 1 2 3 4 5 6 7 8
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
R47 1 2 3
R213 1 2 3 4 5 6 7 8
EN-05047
EN(H4SO)(diag)-209

Step CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel tank pressure sensor connector and engine ground. Connector & terminal (R47) No. 1 Engine ground: Check Yes Is the measured value 7.95 kPa Go to step 2. (59.6 mmHg, 2.35 inHg) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is the measured value 7.95 kPa Repair the short circuit to power (59.6 mmHg, 2.35 inHg) or more? supply in the harness between the ECM and fuel tank pressure sensor connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact in ECM connector Poor contact of coupling connector CHECK POOR CONTACT. Is there poor contact in fuel tank Repair the poor Replace the fuel Check for poor contact of the fuel tank pressure pressure sensor connector? contact in the fuel tank pressure sensensor connector. tank pressure sensor. <Ref. to EC(H4SO)-12, sor connector. Fuel Tank Pressure Sensor.>
EN(H4SO)(diag)-210

BL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-126, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3 SBF-7 6 4 2 1 B47 C: B136 D: B137
BATTERY
ECM
C17
C28
14
15
41
R1
48 2
B97
D29
B21 E2
7 R46 6
R15 1 5 R213 R68 1 2 1
R67
R144 1 2
E4
DRAIN VALVE
B21
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R68 1 2
R144 1 2
E4 1 2
R67 1 2 3 4 5 6
EN-06840
EN(H4SO)(diag)-211

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H4SO)-52, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H4SO)-16, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H4SO)-7, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)51, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H4SO)-13, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 0.5 mm (0.020 in) dia. on evap- the evaporation 1) Turn the ignition switch to OFF. oration line? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H4SO)-65, tor. Fuel Delivery and Evaporation Lines.>
EN(H4SO)(diag)-212

Step CHECK CANISTER. Check Yes Is the canister damaged or is Repair or replace there a hole of more than 0.5 mm the canister. <Ref. (0.020 in) dia. in it? to EC(H4SO)-5, Canister.> Is the fuel tank damaged or is Repair or replace there any hole of more than the fuel tank. <Ref. to FU(H4SO)-45, 0.5 mm (0.020 in) dia. in it? Fuel Tank.> Is there any hole of more than Repair or replace 0.5 mm (0.020 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system? No Go to step 9.
Go to step 10.
10
EN(H4SO)(diag)-213

BM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-126, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor Fuel filler cap loose or lost CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3 SBF-7 6 4 2 1 B47 C: B136 D: B137
BATTERY
ECM
C17
C28
14
15
41
R1
48 2
B97
D29
B21 E2
7 R46 6
R15 1 5 R213 R68 1 2 1
R67
R144 1 2
E4
DRAIN VALVE
B21
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R68 1 2
R144 1 2
E4 1 2
R67 1 2 3 4 5 6
EN-06840
EN(H4SO)(diag)-214

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H4SO)-52, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H4SO)-16, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H4SO)-7, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)51, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H4SO)-13, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONAre there any disconnected, Repair or replace Go to step 8. TROL SYSTEM LINE. broken or clogged evaporation the evaporation 1) Turn the ignition switch to OFF. lines? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H4SO)-65, tor. Fuel Delivery and Evaporation Lines.>
EN(H4SO)(diag)-215

Step CHECK CANISTER. Check Is the canister damaged? Yes Repair or replace the canister. <Ref. to EC(H4SO)-5, Canister.> Repair or replace the fuel tank. <Ref. to FU(H4SO)-45, Fuel Tank.> Repair or replace the hoses or pipes. No Go to step 9.
Is the fuel tank damaged?
Go to step 10.
10
Are there holes, cracks, clogging, or disconnections, misconnection of hoses or pipes in evaporative emission control system?
EN(H4SO)(diag)-216

BN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-127, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3 SBF-7 6 4 2 1 B47 C: B136 D: B137
BATTERY
ECM
C17
C28
14
15
41
R1
48 2
B97
D29
B21 E2
7 R46 6
R15 1 5 R213 R68 1 2 1
R67
R144 1 2
E4
DRAIN VALVE
B21
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R68 1 2
R144 1 2
E4 1 2
R67 1 2 3 4 5 6
EN-06840
EN(H4SO)(diag)-217

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Measure the resistance between the purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE. Measure the resistance of harness between ECM and purge control solenoid valve connector. Connector & terminal (B137) No. 29 (E4) No. 1: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair the ground short circuit of harness between ECM and purge control solenoid valve connector.
CHECK PURGE CONTROL SOLENOID Is the resistance between 10 VALVE. 100 :? 1) Remove the purge control solenoid valve. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 No. 2: CHECK POWER SUPPLY TO PURGE CON- Is the voltage 10 V or more? TROL SOLENOID VALVE. 1) Turn the ignition switch to ON. 2) Measure the voltage between purge control solenoid valve and engine ground. Connector & terminal (E4) No. 2 (+) Engine ground ():
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and purge control solenoid valve connector Poor contact of coupling connector Replace the purge control solenoid valve. <Ref. to EC(H4SO)-7, Purge Control Solenoid Valve.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and purge control solenoid valve connector Poor contact of coupling connector Poor contact of main relay connector
Repair the poor contact of purge control solenoid valve connector.
EN(H4SO)(diag)-218

BO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-128, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3 SBF-7 6 4 2 1 B47 C: B136 D: B137
BATTERY
ECM
C17
C28
14
15
41
R1
48 2
B97
D29
B21 E2
7 R46 6
R15 1 5 R213 R68 1 2 1
R67
R144 1 2
E4
DRAIN VALVE
B21
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R68 1 2
R144 1 2
E4 1 2
R67 1 2 3 4 5 6
EN-06840
EN(H4SO)(diag)-219

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? PURGE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground (): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 :? VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 No. 2: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and purge control solenoid valve connector.
Replace the purge Repair the poor control solenoid contact of ECM valve. <Ref. to connector. EC(H4SO)-7, Purge Control Solenoid Valve.>
EN(H4SO)(diag)-220

BP:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-129, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> No Replace the fuel level sensor and fuel sub level sensor. <Ref. to FU(H4SO)-57, Fuel Level Sensor.> <Ref. to FU(H4SO)-58, Fuel Sub Level Sensor.>
BQ:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

NOTE: For the diagnostic procedure, refer to DTC P0463. <Ref. to EN(H4SO)(diag)-221, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BR:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-133, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0462 or P0463 displayed on the Subaru Select Monitor? Yes Check the combination meter. <Ref. to IDI-13, CHECK FUEL LEVEL SENSOR, INSPECTION, Combination Meter System.> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
EN(H4SO)(diag)-221

BS:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-135, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 Step Check Yes CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0464 displayed on the Check the combidisplay? nation meter. <Ref. to IDI-13, CHECK FUEL LEVEL SENSOR, INSPECTION, Combination Meter System.> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
BT:DTC P0500 VEHICLE SPEED SENSOR A

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-138, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 Step CHECK DTC OF ABS. Check DTC of ABS. Check Is DTC of ABS displayed? Yes No Perform the diag- Repair the poor nosis according to contact of ECM DTC. <Ref. to connector. ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-222

BU:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-139, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start the engine. Engine does not start. Improper idling Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-223

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> Is the air cleaner element Replace the air excessively clogged? cleaner element. <Ref. to IN(H4SO)4, Air Cleaner Element.> Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control. No Go to step 2.
CHECK AIR CLEANER ELEMENT. 1) Turn the ignition switch to OFF. 2) Check the air cleaner element.
Go to step 3.
CHECK ELECTRONIC THROTTLE CONTROL. 1) Remove the electronic throttle control. 2) Check the electronic throttle control.
Perform the diagnosis of DTC P2101. <Ref. to EN(H4SO)(diag)276, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-224

BV:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-140, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-225

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> Repair air suction Go to step 3. and leaks.
CHECK AIR INTAKE SYSTEM. 1) Start and idle the engine. 2) Check the following items. Loose installation of intake manifold and throttle body Cracks of intake manifold gasket and throttle body gasket Disconnection of vacuum hoses CHECK ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control. 3) Check the electronic throttle control.
Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control.
Perform the diagnosis of DTC P2101. <Ref. to EN(H4SO)(diag)276, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-226

BW:DTC P0512 STARTER REQUEST CIRCUIT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-141, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY No. 21 2 B72 15 13 IGNITION SWITCH 3 SBF-6 MAIN SBF
STARTER RELAY B225
16
14
INHIBITOR SWITCH AT MT AT MT 11 12 B12 T3 9 6 T7 P R N D
B106 2
MT
CLUTCH START SWITCH
AT
MT
M
AT B14 20 B136 ECM
B225 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
32
B106 1 2
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B72 1 2 3 4 5 6
B12 1 2 3 4 5 6 7 8 9 10 11 12
T7 1 2 3 4 5 6 7 8 9
EN-06830
EN(H4SO)(diag)-227

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> Repair the short circuit to power in the harness between the ECM and ignition switch. No Go to step 2.
CHECK HARNESS BETWEEN ECM AND IG- Is the voltage 10 V or more? NITION SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 32 (+) Chassis ground ():
BX:DTC P0600 SERIAL COMMUNICATION LINK

NOTE: For the diagnostic procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
EN(H4SO)(diag)-228

BY:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-145, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine does not start. Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY
A: B134
E
36
34
35
37
E
B: B135
B72
B47
B21
A: 1 8 9 18 19 28 29 2 10 20 30
B134
C:
B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06831
EN(H4SO)(diag)-229

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
BZ:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
NOTE: For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4SO)(diag)-231, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-230

CA:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-147, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 3 5 6 4 1 2 B47 No. 12 4 C24 A7 B2 B5 B27 3 TO IGNITION COIL & IGNITOR ASSY SBF-7 No. 13 B72 IGNITION SWITCH SBF-6 MAIN SBF
BATTERY
A: B134
B: B135 ECM
C: B136
D: B137
*
A19 D4 D5 A29 A28 A18 A5 D1 D2 D3 D7 C6
B122
* *
35 18 36 20 39 38 19 34 37 52 17 6 B21 E2
5 1 2 3
E57
E
B: B135 C: B136 5 6 14 15 16 25 26 27 33 34 35
B122 1 2 3 4 5 6 7 8
B47
B21
A: 1 8 9 18 19 28 29 2 10 20 30
B134
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
D:
B72
E57 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6
1 2 3 4 5 6
EN-06842
EN(H4SO)(diag)-231

Step Check Yes CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 13 V? Go to step 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. Is the voltage 13 15 V? Go to step 3. 1) Start the engine. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 19 (E57) No. 5: (B134) No. 29 (E57) No. 3: No Repair the open or ground short circuit of power supply circuit.
CHECK ECM GROUND HARNESS. Is the voltage less than 1 V? Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 5 (+) Chassis ground (): (B137) No. 1 (+) Chassis ground (): (B137) No. 2 (+) Chassis ground (): (B137) No. 3 (+) Chassis ground (): (B137) No. 7 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the following item. Open circuit of ground circuit Retightening of engine ground terminals Poor contact of coupling connector
CB:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)

NOTE: For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO)(diag)-276, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CC:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

NOTE: For the diagnostic procedure, refer to AT section. <Ref. to 4AT(diag)-2, Basic Diagnostic Procedure.>
EN(H4SO)(diag)-232

CD:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-152, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C: B136 C: B136 ECM 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
*
31 6
B122
B25
* *
B25 MT AT 2 NEUTRAL POSITION SWITCH T2 T2 1 B25
1 2
B12 1 2 3 4 5 6 7 8 9 10 11 12
INHIBITOR SWITCH P 12 11 B12 T3 6 9 T7 R N D
T7 1 2 3 4 5 6 7 8 9
B122 1 2 3 4 5 6 7 8
AT
M
MT B14 AT
MT
TO STARTER RELAY
EN-06642
EN(H4SO)(diag)-233

Check Yes Are there any faults in the select Repair or adjust cable? the select cable. <Ref. to CS-28, Select Cable.> CHECK INPUT SIGNAL OF ECM. Is the voltage 10 V or more? Repair the poor 1) Turn the ignition switch to ON. contact of ECM 2) Place the select lever in other than P range connector. and N range. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Go to step 4. TRANSMISSION HARNESS CONNECTOR. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and transmission harness connector (T3). 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 31 Chassis ground: CHECK TRANSMISSION HARNESS CONIs the resistance 1 M: or Replace the inhibiNECTOR. more? tor switch. <Ref. to 1) Disconnect the connector from inhibitor 4AT-46, Inhibitor switch. Switch.> 2) Measure the resistance between the transmission harness connector and engine ground. Connector & terminal (T3) No. 11 Engine ground: Step CHECK SELECT CABLE. No Go to step 2.
Go to step 3.
Repair the ground short circuit of harness between ECM and transmission harness connector.
Repair the ground short circuit of harness between transmission harness connector and inhibitor switch connector.
EN(H4SO)(diag)-234

CE:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-153, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C: B136 C: B136 ECM 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
*
31 6
B122
B25
* *
1 2
B12 1 2 3 4 5 6 7 8 9 10 11 12
T7 1 2 3 4 5 6 7 8 9
B122 1 2 3 4 5 6 7 8
AT
M
MT B14 AT
MT
TO STARTER RELAY
EN-06642
EN(H4SO)(diag)-235

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage 10 V or more? 1) Turn the ignition switch to ON. 2) Place the shift lever in a position other than neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or NEUTRAL POSITION SWITCH CONNECmore? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and transmission harness connector (T2). 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 31 Chassis ground: Yes Repair the poor contact of ECM connector. No Go to step 2.
Repair the short circuit of transmission harness or replace neutral position switch. <Ref. to 5MT-35, Switches and Harness.>
EN(H4SO)(diag)-236

CF:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-154, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C: B136 C: B136 ECM 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
*
31 6
B122
B25
* *
1 2
B12 1 2 3 4 5 6 7 8 9 10 11 12
T7 1 2 3 4 5 6 7 8 9
B122 1 2 3 4 5 6 7 8
AT
M
MT B14 AT
MT
TO STARTER RELAY
EN-06642
EN(H4SO)(diag)-237

Step CHECK SELECT CABLE. Check Yes Are there any faults in the select Repair or adjust cable? the select cable. <Ref. to CS-28, Select Cable.> Is the voltage less than 1 V? Repair the poor contact of ECM connector. No Go to step 2.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and inhibitor switch connector Poor contact of coupling connector CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 :? Replace the inhibi- Repair the harness tor switch. <Ref. to and connector. Measure the resistance of harness between 4AT-46, Inhibitor inhibitor switch connector and engine ground. NOTE: Connector & terminal Switch.> In this case, repair (T7) No. 9 Engine ground: the following item: Open circuit in harness between inhibitor switch connector and starter motor ground line Poor contact of coupling connector Poor contact in starter motor connector Poor contact in starter motor ground Starter motor
CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground with select lever at P range and N range. Connector & terminal (B136) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 :? Go to step 4. HIBITOR SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and inhibitor switch. 3) Measure the resistance of harness between ECM and inhibitor switch connector. Connector & terminal (B136) No. 31 (T7) No. 6:
Go to step 3.
EN(H4SO)(diag)-238

CG:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-155, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C: B136 C: B136 ECM 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
*
31 6
B122
B25
* *
1 2
B12 1 2 3 4 5 6 7 8 9 10 11 12
T7 1 2 3 4 5 6 7 8 9
B122 1 2 3 4 5 6 7 8
AT
M
MT B14 AT
MT
TO STARTER RELAY
EN-06642
EN(H4SO)(diag)-239

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage less than 1 V? 1) Turn the ignition switch to ON. 2) Place the shift lever in neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? NEUTRAL POSITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect connectors from the ECM and transmission harness. 3) Measure the resistance of harness between ECM and transmission harness connector. Connector & terminal (B136) No. 31 (T2) No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? NEUTRAL POSITION SWITCH CONNECTOR. Measure the resistance of harness between ECM and transmission harness connector. Connector & terminal (B136) No. 6 (T2) No. 1: Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair the open circuit in harness between ECM and transmission harness connector.
Go to step 4.
CHECK NEUTRAL POSITION SWITCH. Is the resistance less than 1 :? 1) Place the shift lever in neutral. 2) Measure the resistance between transmission harness connector terminals. Connector & terminal (T2) No. 1 No. 2:
Repair the poor contact of transmission harness connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between transmission harness connector and engine ground Poor contact of coupling connector Repair the open circuit of transmission harness or replace the neutral position switch. <Ref. to 5MT-35, Switches and Harness.>
EN(H4SO)(diag)-240

CH:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-156, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-241

Step Check CHECK FRONT OXYGEN (A/F) SENSOR Has water entered the connecCONNECTOR AND COUPLING CONNECtor? TOR. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 9 (E22) No. 1: (B135) No. 8 (E22) No. 3: CHECK POOR CONTACT. Is there poor contact in front Check for poor contact in the front oxygen (A/F) oxygen (A/F) sensor connecsensor connector. tor? Yes Completely remove any water inside. Go to step 3. No Go to step 2.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Repair the poor Replace the front contact of the front oxygen (A/F) senoxygen (A/F) sensor. <Ref. to sor connector. FU(H4SO)-35, Front Oxygen (A/F) Sensor.>
EN(H4SO)(diag)-242

CI: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-158, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-243

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 9 Chassis ground: (B135) No. 8 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 9 (+) Chassis ground (): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 8 (+) Chassis ground (): Check Yes Has water entered the connec- Completely tor? remove any water inside. Is the resistance 1 M: or Go to step 3. more? No Go to step 2.
Go to step 5.
Go to step 4.
Is the voltage 4.95 V or more? Go to step 5.
CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 8 V or more? Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 9 (+) Chassis ground (): (B135) No. 8 (+) Chassis ground ():
Repair the short circuit to power in the harness between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).>
Replace the front oxygen (A/F) sensor. <Ref. to FU(H4SO)-35, Front Oxygen (A/F) Sensor.> Repair the poor contact of ECM connector.
CJ:DTC P1160 RETURN SPRING FAILURE

EN(H4SO)(diag)-244

CK:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-161, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3 SBF-7 6 4 2 1 B47 C: B136 D: B137
BATTERY
ECM
C17
C28
14
15
41
R1
48 2
B97
D29
B21 E2
7 R46 6
R15 1 5 R213 R68 1 2 1
R67
R144 1 2
E4
DRAIN VALVE
B21
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R68 1 2
R144 1 2
E4 1 2
R67 1 2 3 4 5 6
EN-06840
EN(H4SO)(diag)-245

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 28 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND PRESSURE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the ECM and pressure control solenoid valve. 3) Measure the resistance between pressure control solenoid valve and chassis ground. Connector & terminal (R68) No. 2 Chassis ground: CHECK HARNESS BETWEEN ECM AND PRESSURE CONTROL SOLENOID VALVE. Measure the resistance of harness between ECM and pressure control solenoid valve connector. Connector & terminal (B136) No. 28 (R68) No. 2: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair the ground short circuit of harness between ECM and pressure control solenoid valve connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and pressure control solenoid valve connector Poor contact of coupling connector Replace the presCHECK PRESSURE CONTROL SOLENOID Is the resistance between 10 Go to step 5. 100 :? sure control soleVALVE. noid valve. <Ref. to Measure the resistance between pressure conEC(H4SO)-13, trol solenoid valve terminals. Pressure Control Terminals Solenoid Valve.> No. 1 No. 2: CHECK POWER SUPPLY TO THE PRESIs the voltage 10 V or more? Repair the poor Repair the harness SURE CONTROL SOLENOID VALVE. contact of pressure and connector. 1) Turn the ignition switch to ON. control solenoid NOTE: 2) Measure the voltage between pressure convalve connector. In this case, repair trol solenoid valve and chassis ground. the following item: Connector & terminal Open circuit in (R68) No. 1 (+) Chassis ground (): harness between main relay and pressure control solenoid valve connector Poor contact of coupling connector Poor contact of main relay connector
EN(H4SO)(diag)-246

CL:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-163, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3 SBF-7 6 4 2 1 B47 C: B136 D: B137
BATTERY
ECM
C17
C28
14
15
41
R1
48 2
B97
D29
B21 E2
7 R46 6
R15 1 5 R213 R68 1 2 1
R67
R144 1 2
E4
DRAIN VALVE
B21
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R68 1 2
R144 1 2
E4 1 2
R67 1 2 3 4 5 6
EN-06840
EN(H4SO)(diag)-247

Step CHECK HARNESS BETWEEN ECM AND PRESSURE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the ECM and pressure control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 28 (+) Chassis ground (): CHECK PRESSURE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between pressure control solenoid valve terminals. Terminals No. 1 No. 2: Check Is the voltage 10 V or more? Yes No Repair the short Go to step 2. circuit to power supply in the harness between the ECM and pressure control solenoid valve connector.
Is the resistance less than 1 :? Replace the pres- Repair the poor sure control sole- contact of ECM noid valve. <Ref. to connector. EC(H4SO)-13, Pressure Control Solenoid Valve.>
EN(H4SO)(diag)-248

CM:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-165, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper fuel supply CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY
5 3
BATTERY
SBF-7
6 4 2 1 B47
R46 7 14 B97 R1 R15 6 1
R67 1 2 R213 R144

DRAIN VALVE
17 B136 ECM
B47 1 3 5 2 4 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
R67 1 2 3 4 5 6
R213 1 2 3 4 5 6 7 8
R144 1 2
EN-06841
EN(H4SO)(diag)-249

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> Replace the drain hose. Repair the poor contact of ECM connector. No Go to step 2.
2 3
CHECK DRAIN HOSE. Is there clogging in the drain Check the drain hose for clogging. hose? CHECK DRAIN VALVE OPERATION. Does the drain valve operate? 1) Turn the ignition switch to OFF. 2) Connect the delivery (test) mode connector at the lower portion of instrument panel (on the drivers side). 3) Turn the ignition switch to ON. 4) Operate the drain valve. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-51, Compulsory Valve Operation Check Mode.>
Go to step 3. Replace the drain valve. <Ref. to EC(H4SO)-16, Drain Valve.>
EN(H4SO)(diag)-250

CN:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-167, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134
ECM
30
B134 1 2 8 9 10 18 19 20 28 29 30 B21 E2 10 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
E61 1 2
2 1 E61 PCV DIAGNOSIS CONNECTOR
E
EN-04049
EN(H4SO)(diag)-251

Step Check Yes CHECK BLOW-BY HOSE. Is there any disconnection or Repair or replace Check the condition of the blow-by hose. crack in blow-by hose? the blow-by hose. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 3. PCV HOSE ASSEMBLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and PCV hose assembly. 3) Measure the resistance of harness between ECM and PCV hose assembly. Connector & terminal (B134) No. 30 (E61) No. 2: No Go to step 2. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and PCV hose assembly Poor contact of coupling connector Repair the ground short circuit of harness between ECM and PCV hose assembly. Repair the open circuit of harness between PCV hose assembly and engine ground.
1 2
CHECK HARNESS BETWEEN ECM AND PCV HOSE ASSEMBLY. Measure the resistance between PCV hose assembly and chassis ground. Connector & terminal (B134) No. 30 Chassis ground: CHECK GROUND CIRCUIT OF PCV HOSE ASSEMBLY. Measure the resistance of harness between PCV hose assembly and engine ground. Connector & terminal (E61) No. 1 Engine ground: CHECK THE PCV HOSE ASSEMBLY. Measure the resistance between the PCV hose assembly terminals. Terminals No. 1 No. 2:
Go to step 4.
Is the resistance less than 1 :? Repair the poor Replace the PCV contact in ECM hose assembly. and PCV hose assembly connector.
EN(H4SO)(diag)-252

CO:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
NOTE: For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H4SO)(diag)-254, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CP:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
NOTE: For the diagnostic procedure, refer to DTC P1499. <Ref. to EN(H4SO)(diag)-257, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CQ:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
CR:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
CS:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
CT:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
EN(H4SO)(diag)-253

CU:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-169, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine breathing CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
EN(H4SO)(diag)-254

WIRING DIAGRAM:
B21 5 2
EGR VALVE E18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 3 4 6
B134 1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
E2 26 25 29 30 B21 B134 ECM 9 8 10 20
EN-06839
EN(H4SO)(diag)-255

Step Check CHECK POWER SUPPLY TO EGR VALVE. Is the voltage 10 V or more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between EGR valve connector and engine ground. Connector & terminal (E18) No. 2 (+) Engine ground (): (E18) No. 5 (+) Engine ground (): Yes Go to step 2. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between EGR valve and main relay connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and EGR valve connector Poor contact of coupling connector Repair the ground short in harness between ECM and EGR valve connector.
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 3. EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM and EGR valve connector. Connector & terminal DTC P1492; (B134) No. 8 (E18) No. 3: DTC P1494; (B134) No. 9 (E18) No. 1: DTC P1496; (B134) No. 10 (E18) No. 4: DTC P1498; (B134) No. 20 (E18) No. 6: CHECK HARNESS BETWEEN ECM AND EGR VALVE CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal DTC P1492; (B134) No. 8 Chassis ground: DTC P1494; (B134) No. 9 Chassis ground: DTC P1496; (B134) No. 10 Chassis ground: DTC P1498; (B134) No. 20 Chassis ground: CHECK POOR CONTACT. Check poor contact in ECM and EGR valve connector. Is the resistance 1 M: or more? Go to step 4.
Is there poor contact in ECM or Repair the poor EGR valve connector? contact in ECM or EGR valve connector.
Replace the EGR valve. <Ref. to FU(H4SO)-29, EGR Valve.>
EN(H4SO)(diag)-256

CV:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-171, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine breathing CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
EN(H4SO)(diag)-257

WIRING DIAGRAM:
B21 5 2
EGR VALVE E18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 3 4 6
B134 1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
E2 26 25 29 30 B21 B134 ECM 9 8 10 20
EN-06839
Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal DTC P1493; (B134) No. 8 (+) Chassis ground (): DTC P1495; (B134) No. 9 (+) Chassis ground (): DTC P1497; (B134) No. 10 (+) Chassis ground (): DTC P1499; (B134) No. 20 (+) Chassis ground ():
Yes No Repair the power Repair the poor supply short circuit contact of ECM of harness connector. between ECM and EGR valve connector.
EN(H4SO)(diag)-258

CW:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-174, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY
A: B134
E
36
34
35
37
E
B: B135
B72
B47
B21
A: 1 8 9 18 19 28 29 2 10 20 30
B134
C:
B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06831
EN(H4SO)(diag)-259

Step CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 5 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 5 Chassis ground: CHECK FUSE NO. 13 (IN MAIN FUSE BOX). Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair the ground short circuit of harness between ECM and battery terminal.
Replace the fuse.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and battery Poor contact in ECM connector Poor contact of battery terminal
EN(H4SO)(diag)-260

CX:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-176, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. Engine keeps running at a lower speed than the specified idle speed. Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 6 4 2 1 B47
BATTERY SBF-7
B137
ECM
10
48
42
43
E5 2 1 2 1
E16 2 B21 1
FUEL INJECTOR No. 1
FUEL INJECTOR No. 2
FUEL INJECTOR No. 3
E5 E6 1 2
E16 E17
B47 1 3 5 2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
44
EN-06833
EN(H4SO)(diag)-261

4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-262

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> Go to step 3. Replace engine oil. <Ref. to LU(H4SO)-10, REPLACEMENT, Engine Oil.> Repair the exhaust Go to step 4. system. Repair the air Go to step 5. intake system. Repair the following item. Fuel pressure is too high: Clogged fuel line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel line Replace the engine coolant temperature sensor. <Ref. to FU(H4SO)-22, Engine Coolant Temperature Sensor.>
CHECK ENGINE OIL.
Is there a proper amount of engine oil?
3 4
Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 339.5 Go to step 6. 360.5 kPa (3.5 3.7 kg/cm2, WARNING: Place NO OPEN FLAMES signs near the 49 52 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. <Ref. to ME(H4SO)26, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Go to step 7. SENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual.
CHECK EXHAUST SYSTEM.
EN(H4SO)(diag)-263

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): Check Is the measured value 2.0 5.0 g/s (0.26 0.66 lb/m)? Yes Go to step 8. No Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
Subtract ambient temperature Go to step 9. from intake air temperature. Is the obtained value 10 50C (18 90F)?
Check the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
Go to step 14.
Go to step 10.
EN(H4SO)(diag)-264

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Go to step 11. FUEL INJECTOR. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 Engine ground: #2 (E16) No. 1 Engine ground: #3 (E6) No. 1 Engine ground: #4 (E17) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 12. FUEL INJECTOR. Measure the resistance of harness between ECM and fuel injector on faulty cylinders. Connector & terminal #1 (B137) No. 8 (E5) No. 1: #2 (B137) No. 9 (E16) No. 1: #3 (B137) No. 10 (E6) No. 1: #4 (B137) No. 11 (E17) No. 1: No Repair the short circuit to ground in harness between ECM and fuel injector connector.
10
11
12
13
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector Replace the faulty fuel injector. <Ref. to FU(H4SO)-30, Fuel Injector.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the main relay connector and fuel injector connector on faulty cylinders Poor contact of coupling connector Poor contact of main relay connector Go to step 15.
14
CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground ():
Repair the short circuit to power in the harness between the ECM and fuel injector.
EN(H4SO)(diag)-265

Step CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK INSTALLATION CONDITION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. Check Yes No Is the resistance less than 1 :? Replace the faulty Go to step 16. fuel injector. <Ref. to FU(H4SO)-30, Fuel Injector.>
15
16
17
18
19
20
21
22
Is the camshaft position sensor Tighten the cam- Go to step 17. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. CHECK CRANK SPROCKET. Is the crank sprocket rusted or Replace the crank Go to step 18. Remove the timing belt cover. <Ref. to does it have broken teeth? sprocket. <Ref. to ME(H4SO)-43, REMOVAL, Timing Belt Cover.> ME(H4SO)-50, Crank Sprocket.> CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 19. TIMING BELT. from its proper position? tion condition of Turn the crankshaft using ST, and align the timing belt. <Ref. to alignment mark on crank sprocket with alignME(H4SO)-44, ment mark on cylinder block. Timing Belt.> ST 499987500 CRANKSHAFT SOCKET CHECK ELECTRONIC THROTTLE CONIs the resistance less than 1 :? Go to step 20. Replace the elecTROL RELAY. tronic throttle con1) Turn the ignition switch to OFF. trol relay. <Ref. to 2) Remove the electronic throttle control relay. FU(H4SO)-42, 3) Connect the battery to terminals No. 5 and Electronic Throttle No. 6 of electronic throttle control relay. Control Relay.> 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 8 No. 7: CHECK POWER SUPPLY OF ELECTRONIC Is the voltage 10 V or more? Go to step 21. Repair the open or THROTTLE CONTROL RELAY. ground short circuit Measure the voltage between electronic throttle of power supply control relay connector and chassis ground. circuit. Connector & terminal (B362) No. 8 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? Repair the short Go to step 22. ELECTRONIC THROTTLE CONTROL REcircuit to power in LAY. the harness 1) Disconnect the connectors from ECM. between ECM and 2) Turn the ignition switch to ON. electronic throttle 3) Measure the voltage between electronic control relay conthrottle control relay connector and chassis nector. ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): Is the resistance 1 M: or Go to step 23. Repair the short CHECK HARNESS BETWEEN ECM AND more? circuit in harness ELECTRONIC THROTTLE CONTROL RELAY. to ground between 1) Turn the ignition switch to OFF. ECM and elec2) Measure the resistance between electronic tronic throttle conthrottle control relay connector and chassis trol relay ground. connector. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 7 Chassis ground:
EN(H4SO)(diag)-266

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 7: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Check Yes Is the resistance less than 1 :? Go to step 24. No Repair the open circuit in harness between ECM and electronic throttle control relay connector.
23
24
Go to step 25.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
25
Go to step 26.
26
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 27. ELECTRONIC THROTTLE CONTROL. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 (E57) No. 6: (B134) No. 28 (E57) No. 4: (B134) No. 29 (E57) No. 3:
27
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector
EN(H4SO)(diag)-267

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) Engine ground (): (E57) No. 4 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 (B134) No. 18: (B134) No. 19 (B134) No. 28: CHECK SENSOR OUTPUT. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> CHECK SENSOR OUTPUT. Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> Check Yes No Is the voltage 4.85 V or more? Repair the short Go to step 29. circuit to power in the harness between ECM and electronic throttle control connector.
28
29
Go to step 30.
30
Go to step 31.
Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4SO)-12, Throttle Body.> Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4SO)-12, Throttle Body.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Go to step 34.
31
Go to step 32.
32
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 33. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B137) No. 5 (E57) No. 2: (B137) No. 4 (E57) No. 1: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) Engine ground (): (E57) No. 1 (+) Engine ground (): Is the voltage 5 V or more? Repair the short circuit to power in the harness between ECM and electronic throttle control.
33
EN(H4SO)(diag)-268

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 Engine ground: (E57) No. 1 Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between the electronic throttle control connector terminals. Connector & terminal (E57) No. 2 (E57) No. 1: CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers. Check Is the resistance 1 M: or more? Yes Go to step 35. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
34
35
Go to step 36.
Repair the short circuit of harness between ECM and electronic throttle control connector. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the electronic throttle control. <Ref. to FU(H4SO)-12, Throttle Body.> Replace the electronic throttle control. <Ref. to FU(H4SO)-12, Throttle Body.>
36
37
Is the resistance 50 : or less? Go to step 38.
38
Does the valve return to the Repair the poor contact of ECM specified position? Standard value: 3 mm (0.12 in) from fully connector. closed position
CY:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
NOTE: Refer to DTC P2097 for diagnostic procedure. <Ref. to EN(H4SO)(diag)-270, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-269

CZ:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-180, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B138 1 2 3 4 5 6 7 8
3 2 1 6 5 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 51 4 3 B21
E
A: B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06835
EN(H4SO)(diag)-270

A/F, OXYGEN SENSOR RELAY SBF-5 6 4 5 3 2 1 B327 4 1 3 REAR OXYGEN SENSOR E23 B21 50 E2 2 E23
BATTERY
B327 1 3 5 2 4 6 B138 1 2 3 4 5 6 7 8
1 2 3 4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42
E2 53 19 1 B21
35 43 48 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
36
34
35
37
52
B21 E2
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-06836
EN(H4SO)(diag)-271

Yes No Check DTC using Go to step 2. List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> CHECK FRONT OXYGEN (A/F) SENSOR Has water entered the connec- Completely Go to step 3. CONNECTOR AND COUPLING CONNECtor? remove any water TOR. inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the harness FRONT OXYGEN (A/F) SENSOR CONNECand connector. TOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM and the following item: front oxygen (A/F) sensor. Open circuit in 3) Measure the resistance of harness between harness between ECM and front oxygen (A/F) sensor connector. ECM and front oxyConnector & terminal gen (A/F) sensor (B135) No. 9 (E22) No. 1: connector (B135) No. 8 (E22) No. 3: Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Go to step 5. Repair the ground FRONT OXYGEN (A/F) SENSOR CONNEC- more? short circuit of harTOR. ness between Measure the resistance between ECM and ECM and front oxychassis ground. gen (A/F) sensor Connector & terminal connector. (B135) No. 9 Chassis ground: (B135) No. 8 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.5 V or more? Go to step 7. Go to step 6. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E22) No. 1 (+) Chassis ground (): CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.95 V or more? Go to step 7. Go to step 8. Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E22) No. 3 (+) Chassis ground (): Repair the poor CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 8 V or more? Repair the short Measure the voltage between front oxygen (A/F) circuit to power in contact of ECM connector. sensor connector and chassis ground. the harness Connector & terminal between ECM and (E22) No. 1 (+) Chassis ground (): front oxygen (A/F) (E22) No. 3 (+) Chassis ground (): sensor connector. After repair, replace the ECM. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).> CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 9. on exhaust system? system. Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?
EN(H4SO)(diag)-272

Step CHECK AIR INTAKE SYSTEM. Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK FUEL PRESSURE. Is the measured value 339.5 Go to step 11. 360.5 kPa (3.5 3.7 kg/cm2, WARNING: Place NO OPEN FLAMES signs near the 49 52 psi)? working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. <Ref. to ME(H4SO)-26, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Go to step 12. SENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value 2.0 Go to step 13. TEMPERATURE SENSOR. 5.0 g/s (0.26 0.66 lb/m)? 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. No Go to step 10.
10
Repair the following item. Fuel pressure is too high: Clogged fuel line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel line
11
Replace the engine coolant temperature sensor. <Ref. to FU(H4SO)-22, Engine Coolant Temperature Sensor.>
12
Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
EN(H4SO)(diag)-273

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Depress the clutch pedal. (MT model) SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Depress the clutch pedal. (MT model) SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value 10 50C (18 90F)? No Check the mass air flow and intake air temperature sensor. <Ref. to FU(H4SO)-28, Mass Air Flow and Intake Air Temperature Sensor.>
13
14
Is the voltage 490 mV or more? Go to step 15.
Go to step 16.
15
Go to step 16.
EN(H4SO)(diag)-274

Step Check Yes CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK FRONT OXYGEN (A/F) SENSOR Is a voltage of 0.8 V or more Replace the front AND REAR OXYGEN SENSOR DATA. maintained for 5 minutes or oxygen (A/F) sen1) Warm up the engine until engine coolant more? sor. <Ref. to temperature is higher than 75C (167F), then FU(H4SO)-35, keep the engine idling for 5 minutes or more. Front Oxygen (A/F) 2) Read the data of rear oxygen sensor signal Sensor.> using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 19. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E23) No. 3: (B134) No. 29 (E23) No. 4: No Go to step 18.
16
17
Go to step 18.
18
19
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E23) No. 3 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H4SO)-37, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact in ECM connector Poor contact of coupling connector
EN(H4SO)(diag)-275

DA:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-182, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-276

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 8 No. 7: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 8 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 7 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 7: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: Check Yes Is the resistance less than 1 :? Go to step 2. No Replace the electronic throttle control relay. <Ref. to FU(H4SO)-42, Electronic Throttle Control Relay.>
Go to step 3.
Repair the short Go to step 4. circuit to power in harness between ECM and electronic throttle control relay.
Go to step 5.
Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.
Repair the open circuit in harness between ECM and electronic throttle control relay connector.
Go to step 7.
EN(H4SO)(diag)-277

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 M: or 1) Connect the connector to ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Yes Go to step 8. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 11.
10
11
CHECK HARNESS BETWEEN ECM AND Is the voltage 4.85 V or more? ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) Engine ground (): (E57) No. 4 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 (B134) No. 18: (B134) No. 19 (B134) No. 28:
Go to step 12.
EN(H4SO)(diag)-278

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> CHECK SENSOR OUTPUT. Is the voltage 1.64 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4SO)(diag)-33, Subaru Select Monitor.> Yes Go to step 13. No Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4SO)-12, Throttle Body.> Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4SO)-12, Throttle Body.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Go to step 16.
12
13
Go to step 14.
14
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 15. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B137) No. 5 (E57) No. 2: (B137) No. 4 (E57) No. 1: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) Engine ground (): (E57) No. 1 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 Engine ground: (E57) No. 1 Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between the electronic throttle control connector terminals. Connector & terminal (E57) No. 2 (E57) No. 1: Is the voltage 5 V or more? Repair the short circuit to power in the harness between ECM and electronic throttle control.
15
16
Go to step 17.
Repair the short circuit to ground in harness between ECM and electronic throttle control.
17
Go to step 18.
Repair the short circuit of harness between ECM and electronic throttle control.
EN(H4SO)(diag)-279

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers. Check Yes Is the resistance less than 5 :? Go to step 19. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the electronic throttle control. <Ref. to FU(H4SO)-12, Throttle Body.> Replace the electronic throttle control. <Ref. to FU(H4SO)-12, Throttle Body.>
18
19
20
Does the valve return to the Repair the poor specified position? Standard contact of ECM value: 3 mm (0.12 in) from fully connector. closed position
EN(H4SO)(diag)-280

DB:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-183, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-06838
EN(H4SO)(diag)-281

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 8 No. 7: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 8 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 7 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 7: Check Yes Is the resistance less than 1 :? Go to step 2. No Replace the electronic throttle control relay. <Ref. to FU(H4SO)-42, Electronic Throttle Control Relay.>
Go to step 3.
Repair the short Go to step 4. circuit to power in the harness between ECM and electronic throttle control relay connector.
Go to step 5.
Is the resistance less than 1 :? Repair the poor contact of ECM connector.
Repair the open circuit in harness between ECM and electronic throttle control relay connector.
EN(H4SO)(diag)-282

DC:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-184, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-283

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Measure the resistance between electronic throttle control relay terminals. Terminals No. 8 No. 7: CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUPPLY. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 21 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Replace the electronic throttle control relay. <Ref. to FU(H4SO)-42, Electronic Throttle Control Relay.>
Repair the short Go to step 3. circuit to power in the harness between ECM and electronic throttle control relay connector.
DD:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE

EN(H4SO)(diag)-284

DE:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-186, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B315 ACCELERATOR PEDAL POSITION SENSOR
1 2 3 4 5 6
B83 B122
B315
1 2 3 4 5 6 7 8
B21
* *
B21 B23 B29 B22 B31 B122 B30 C6 A: B134 B: B135 ECM C: B136 D: B137
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
: TERMINAL No. OPTIONAL ARRANGEMENT 1 2 8 9 10 18 19 20 28 29 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
B: B135
A5 D1 D2 D3 D7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B21 36 34 35 37 52 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06844
EN(H4SO)(diag)-285

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 21 Chassis ground: (B135) No. 23 Chassis ground: (B135) No. 23 (B136) No. 6: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector.
Replace the accelerator pedal. <Ref. to SP(H4SO)-3, Accelerator Pedal.>
Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).>
EN(H4SO)(diag)-286

DF:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-188, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 B122
B315
1 2 3 4 5 6 7 8
B21
* *
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
B: B135
A5 D1 D2 D3 D7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B21 36 34 35 37 52 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06844
EN(H4SO)(diag)-287

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 :? Go to step 2. CELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 23 (B315) No. 6: (B135) No. 29 (B315) No. 5: CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 :? Go to step 3. CELERATOR PEDAL POSITION SENSOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 Chassis ground: No Repair the open circuit in harness between ECM and accelerator pedal position sensor connector.
CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 4.85 V or more? CELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 M: or CELERATOR PEDAL POSITION SENSOR. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B135) No. 21 (B135) No. 23:
Repair the short circuit of harness to power supply between ECM and accelerator pedal position sensor connector. Repair the poor contact of accelerator pedal position sensor connector. Replace the accelerator pedal if defective. <Ref. to SP(H4SO)-3, Accelerator Pedal.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 4.
Repair the short circuit of harness to power supply between ECM and accelerator pedal position sensor connector.
EN(H4SO)(diag)-288

DG:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-190, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 B122
B315
1 2 3 4 5 6 7 8
B21
* *
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
B: B135
A5 D1 D2 D3 D7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B21 36 34 35 37 52 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06844
EN(H4SO)(diag)-289

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 22 Chassis ground: (B135) No. 31 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector.
Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).>
EN(H4SO)(diag)-290

DH:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-192, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 B122
B315
1 2 3 4 5 6 7 8
B21
* *
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
B: B135
A5 D1 D2 D3 D7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B21 36 34 35 37 52 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06844
EN(H4SO)(diag)-291

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 :? Go to step 2. CELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 31 (B315) No. 3: (B135) No. 30 (B315) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and accelerator pedal position sensor connector. Poor contact in joint connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 4.
CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 :? Go to step 3. CELERATOR PEDAL POSITION SENSOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 2 Chassis ground:
EN(H4SO)(diag)-292

DI: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-194, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
ECM A: B134 C: B136 D: B137 A28 A18
E
C6
A19 D4 D5 A29
A5 D1 D2 D3 D7
* *
B122 36 34 35 37 52 20 39 38 19 18 17 6 B21 E2
5 1 2 3
E57
B362
B122 1 2 3 4 5 6 7 8
B21
E57 1 2 3 4 5 6
A: 1 2 8 9 10 18 19 20 28 29 30
B134
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06838
EN(H4SO)(diag)-293

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Go to step 3.
CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) Engine ground (): (E57) No. 4 (+) Engine ground ():
Is the voltage 4.85 V or more? Repair the short circuit to power in the harness between ECM and electronic throttle control connector.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 6.
EN(H4SO)(diag)-294

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 (B134) No. 18: (B134) No. 19 (B134) No. 28: Yes Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4SO)-12, Throttle Body.> No Repair the short circuit to power in the harness between ECM and electronic throttle control connector.
EN(H4SO)(diag)-295

DJ:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-196, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 B122
B315
1 2 3 4 5 6 7 8
B21
* *
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
B: B135
A5 D1 D2 D3 D7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B21 36 34 35 37 52 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06844
EN(H4SO)(diag)-296

Step CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal Main accelerator pedal position sensor signal (B135) No. 23 (+) Chassis ground (): Sub accelerator pedal position sensor signal (B135) No. 31 (+) Chassis ground (): CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) Chassis ground (): (B315) No. 3 (+) Chassis ground (): Check Yes Is the difference in measured Go to step 3. values for the main accelerator pedal position sensor signal and the sub accelerator pedal position sensor signal 0 V? No Go to step 2.
Is the difference in measured values for the main accelerator pedal position sensor signal and the sub accelerator pedal position sensor signal 0 V?
CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 :? Repair the poor CELERATOR PEDAL POSITION SENSOR contact of ECM CONNECTOR. connector. Check the resistance of harness between the accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 Chassis ground: (B315) No. 2 Chassis ground:
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and accelerator pedal position sensor connector. Short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and accelerator pedal position sensor connector. Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector
EN(H4SO)(diag)-297

DK:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4SO)-198, DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO)(diag)80, List of Diagnostic Trouble Code (DTC).> No Replace the ECM. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).> NOTE: The barometric pressure sensor is built into the ECM.
DL:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-199, DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
EN(H4SO)(diag)-298

DM:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4SO)-200, DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4SO)(diag)-50, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4SO)(diag)-41, PROCEDURE, Inspection Mode.>.
EN(H4SO)(diag)-299
General Diagnostic Table

21.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO)-96, Engine Trouble in General.>
Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Ignition parts (*1) 1. Engine stalls during idling. 4) Engine coolant temperature sensor (*2) 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Ignition parts (*1) 5) Air intake system (*5) 6) Fuel injection parts (*4) 2. Rough idling 7) Electronic throttle control 8) Crankshaft position sensor (*3) 9) Camshaft position sensor (*3) 10) Oxygen sensor 11) Fuel pump and fuel pump relay 12) EGR valve 1) Engine coolant temperature sensor 2) Electronic throttle control 3. Engine does not return to idle. 3) Manifold absolute pressure sensor 4) Mass air flow and intake air temperature sensor 5) EGR valve 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Electronic throttle control 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay 6) Engine coolant temperature sensor (*2) 4. Poor acceleration 7) Crankshaft position sensor (*3) 8) Camshaft position sensor (*3) 9) A/C switch and A/C cut relay 10) Engine torque control signal circuit 11) Ignition parts (*1) 12) EGR valve 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 5. Engine stalls, engine sags or hesitates at acceleration. 6) Purge control solenoid valve 7) Fuel injection parts (*4) 8) Electronic throttle control 9) Fuel pump and fuel pump relay 10) EGR valve Symptoms
EN(H4SO)(diag)-300

Symptoms Problem parts 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Fuel pump and fuel pump relay 9) EGR valve 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor 4) Knock sensor 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay 7) EGR valve 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay
6. Surging
7. Spark knock
8. After-burn in exhaust system
*1: Check ignition coil and ignitor assembly and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check fuel injector, fuel pressure regulator and fuel filter. *5: Inspect air leak in air intake system.
EN(H4SO)(diag)-301

EN(H4SO)(diag)-302

GENERAL DESCRIPTION
1. List of Diagnostic Trouble Code (DTC)

A: LIST
DTC P0026 Item Intake Valve Control Solenoid Circuit Range/Performance (Bank 1) Intake Valve Control Solenoid Circuit Range/Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) MAP/MAF - Throttle Position Correlation Intake Valve Control Solenoid Circuit Low (Bank 1) Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Intake Valve Control Solenoid Circuit High (Bank 2) Mass or Volume Air Flow Circuit Range/Performance Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Range/Performance Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Note <Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-10, DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-11, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-13, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-15, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-17, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-19, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-21, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-23, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-24, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-25, DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-25, DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-26, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-28, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-29, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-30, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-31, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-32, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-34, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-35, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-36, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0028
P0030 P0031
P0032
P0037
P0038
P0068 P0076 P0077 P0082 P0083 P0101
P0102 P0103 P0107
P0108
P0111
P0112 P0113 P0117
GD(H4SO)-2

GENERAL DESCRIPTION
DTC P0118 P0122 Item Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/ Switch A Circuit Low Throttle/Pedal Position Sensor/ Switch A Circuit High Insufficient Coolant Temperature for Closed Loop Fuel Control Insufficient Engine Coolant Temperature for Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) System Too Lean (Bank 1) System Too Rich (Bank 1) Fuel Temperature Sensor A Circuit Range/Performance Fuel Temperature Sensor A Circuit Low Input Fuel Temperature Sensor A Circuit High Input Engine Oil Temperature Sensor Circuit Range/Performance Engine Oil Temperature Sensor Low Engine Oil Temperature Sensor High Note <Ref. to GD(H4SO)-37, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-38, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-39, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-40, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-42, DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-44, DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-46, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-48, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-50, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-53, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-55, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-57, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-58, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-63, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-65, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-67, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-68, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-71, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-72, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-73, DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-75, DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-76, DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0123
P0125
P0126
P0128
P0131 P0132 P0133
P0134
P0137 P0138 P0139
P0140
P0171 P0172 P0181
P0182 P0183 P0196
P0197 P0198
GD(H4SO)-3

GENERAL DESCRIPTION
DTC P0222 Item Throttle/Pedal Position Sensor/ Switch B Circuit Low Throttle/Pedal Position Sensor/ Switch B Circuit High Cylinder 1 Misfire Detected Note <Ref. to GD(H4SO)-77, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-78, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0223
P0301 P0302 P0303 P0304 P0327
P0328
P0335 P0336
P0340
P0341
P0400 P0420
P0442
P0447
P0448
P0451
P0452
P0453
<Ref. to GD(H4SO)-79, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Cylinder 2 Misfire Detected <Ref. to GD(H4SO)-85, DTC P0302 CYLINDER 2 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Cylinder 3 Misfire Detected <Ref. to GD(H4SO)-85, DTC P0303 CYLINDER 3 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Cylinder 4 Misfire Detected <Ref. to GD(H4SO)-85, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Knock Sensor 1 Circuit Low <Ref. to GD(H4SO)-86, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (Bank 1 or Single Sensor) (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> Knock Sensor 1 Circuit High <Ref. to GD(H4SO)-87, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (Bank 1 or Single Sensor) (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> Crankshaft Position Sensor A Circuit <Ref. to GD(H4SO)-88, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Crankshaft Position Sensor A Circuit <Ref. to GD(H4SO)-90, DTC P0336 CRANKSHAFT POSITION SENSOR A Range/Performance CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Camshaft Position Sensor A Circuit <Ref. to GD(H4SO)-92, DTC P0340 CAMSHAFT POSITION SENSOR A (Bank 1 or Single Sensor) CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> Camshaft Position Sensor A Circuit <Ref. to GD(H4SO)-94, DTC P0341 CAMSHAFT POSITION SENSOR A Range/Performance (Bank 1 or Single CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), DiagSensor) nostic Trouble Code (DTC) Detecting Criteria.> Exhaust Gas Recirculation Flow <Ref. to GD(H4SO)-96, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Catalyst System Efficiency below <Ref. to GD(H4SO)-99, DTC P0420 CATALYST SYSTEM EFFICIENCY Threshold (Bank 1) BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission Control Sys<Ref. to GD(H4SO)-101, DTC P0442 EVAPORATIVE EMISSION CONTROL tem Leak Detected (Small Leak) SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission Control Sys<Ref. to GD(H4SO)-117, DTC P0447 EVAPORATIVE EMISSION CONTROL tem Vent Control Circuit Open SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission Control Sys<Ref. to GD(H4SO)-119, DTC P0448 EVAPORATIVE EMISSION CONTROL tem Vent Control Circuit Shorted SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission Control Sys<Ref. to GD(H4SO)-121, DTC P0451 EVAPORATIVE EMISSION CONTROL tem Pressure Sensor SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission Control Sys<Ref. to GD(H4SO)-123, DTC P0452 EVAPORATIVE EMISSION CONTROL tem Pressure Sensor Low Input SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission Control Sys<Ref. to GD(H4SO)-125, DTC P0453 EVAPORATIVE EMISSION CONTROL tem Pressure Sensor High Input SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-4

GENERAL DESCRIPTION
DTC P0456 Item Evaporative Emission Control System Leak Detected (Very Small Leak) Evaporative Emission Control System Leak Detected (Fuel Cap Loose/ Off) Evaporative Emission System Purge Control Valve Circuit Low Evaporative Emission System Purge Control Valve Circuit High Fuel Level Sensor A Circuit Range/ Performance Fuel Level Sensor A Circuit Low Fuel Level Sensor A Circuit High Fuel Level Sensor Circuit Intermittent Vehicle Speed Sensor A Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Starter Request Circuit Incorrect Immobilizer Key Serial Communication Link Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (Mil Request) Park/Neutral Switch Input Circuit Low (AT Model) Neutral Switch Input Circuit Low (MT Model) Park/Neutral Switch Input Circuit High (AT Model) Note <Ref. to GD(H4SO)-126, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-126, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-127, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-128, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-129, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-131, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-133, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-135, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-138, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-139, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-140, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-141, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-142, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-143, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-145, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-146, DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-147, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-149, DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-151, DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-152, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-153, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-154, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0457
P0458
P0459
P0461
P0462 P0463 P0464 P0500 P0506
P0507
P0512 P0513 P0600 P0604
P0605
P0607
P0638
P0700 P0851 P0851 P0852
GD(H4SO)-5

GENERAL DESCRIPTION
DTC P0852 P1152 Item Neutral Switch Input Circuit High (MT Model) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Exhaust Gas Recirculation Flow Note <Ref. to GD(H4SO)-155, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-156, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-158, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-160, DTC P1160 RETURN SPRING FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-161, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-163, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-165, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-167, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-169, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-171, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-173, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-174, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-175, DTC P1570 ANTENNA, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-175, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-175, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-175, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1153
P1160 P1400
P1420
Fuel Tank Pressure Control Sol. Valve Circuit High Vent Control Solenoid Valve Function Problem Positive Crankcase Ventilation (Blowby) Function Problem EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input) Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure Key Communication Failure
P1443 P1491
P1492
P1493
P1494
P1495
P1496
P1497
P1498
P1499
P1560 P1570 P1571 P1572 P1574
GD(H4SO)-6

GENERAL DESCRIPTION
DTC P1576 P1577 P1578 P1602 P2096 P2097 P2101 Note <Ref. to GD(H4SO)-175, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.> IMM Control Module EEPROM <Ref. to GD(H4SO)-175, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.> Meter Failure <Ref. to GD(H4SO)-175, DTC P1578 METER FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Control Module Programming Error <Ref. to GD(H4SO)-176, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> Post Catalyst Fuel Trim System Too <Ref. to GD(H4SO)-178, DTC P2096 POST CATALYST FUEL TRIM SYSTEM Lean (Bank 1) TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> Post Catalyst Fuel Trim System Too <Ref. to GD(H4SO)-180, DTC P2097 POST CATALYST FUEL TRIM SYSTEM Rich (Bank 1) TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Actuator Control Motor Circuit <Ref. to GD(H4SO)-182, DTC P2101 THROTTLE ACTUATOR CONTROL Range/Performance MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Actuator Control Motor Circuit <Ref. to GD(H4SO)-183, DTC P2102 THROTTLE ACTUATOR CONTROL Low MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Actuator Control Motor Circuit <Ref. to GD(H4SO)-184, DTC P2103 THROTTLE ACTUATOR CONTROL High MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor A <Ref. to GD(H4SO)-185, DTC P2109 THROTTLE/PEDAL POSITION SENMinimum Stop Performance SOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4SO)-186, DTC P2122 THROTTLE/PEDAL POSITION SENSwitch D Circuit Low Input SOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4SO)-188, DTC P2123 THROTTLE/PEDAL POSITION SENSwitch D Circuit High Input SOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4SO)-190, DTC P2127 THROTTLE/PEDAL POSITION SENSwitch E Circuit Low Input SOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4SO)-192, DTC P2128 THROTTLE/PEDAL POSITION SENSwitch E Circuit High Input SOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Position Sensor Circuit <Ref. to GD(H4SO)-194, DTC P2135 THROTTLE/PEDAL POSITION SENRange/Performance SOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> Accelerator Position Sensor Circuit <Ref. to GD(H4SO)-196, DTC P2138 THROTTLE/PEDAL POSITION SENRange/Performance SOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> Atmospheric Pressure Sensor Range/ <Ref. to GD(H4SO)-198, DTC P2227 BAROMETRIC PRESSURE CIRCUIT Performance RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Barometric Pressure Circuit Low <Ref. to GD(H4SO)-199, DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Barometric Pressure Circuit High <Ref. to GD(H4SO)-200, DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Item EGI Control Module EEPROM
P2102 P2103 P2109
P2122
P2123
P2127
P2128
P2135
P2138
P2227
P2228 P2229
GD(H4SO)-7
Diagnostic Trouble Code (DTC) Detecting Criteria

GENERAL DESCRIPTION
2. Diagnostic Trouble Code (DTC) Detecting Criteria

A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
Judge as NG with either Low NG or High NG. A variable valve lift diagnosis oil pressure switch is installed for diagnosis. It is possible to determine whether the intake valve is in high mode (increase the amount of lift) or in low mode (suppressing the amount of lift) when the variable valve lift diagnosis oil pressure switch is turned ON or OFF. Normal
Oil switching solenoid valve duty Large Minimum Intake valve High mode Low mode Variable valve lift diagnosis oil pressure switch ON OFF
Low NG When the variable valve lift diagnosis oil pressure switch remains OFF even though the intake valve tried to enter high mode (oil switching solenoid valve duty is large), this is judged as a Low NG. High NG When the variable valve lift diagnosis oil pressure switch remains ON even though the intake valve tried to enter low mode (oil switching solenoid valve duty is small), this is judged as a High NG.
2. COMPONENT DESCRIPTION
The variable valve lift system optimizes the intake valve lift by switching between the low lift cam and the high lift cam according to the engine speed. The amount of intake valve lift is varied by controlling the oil switching solenoid valve duty according to signals from the ECM.
(A) (B) EN-05565
(A)
Low lift
(B)
High lift
GD(H4SO)-8

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Battery voltage After engine starting Engine oil temperature Variable valve lift control Enable Conditions t 10.9 V t 6000 ms t 15 C (59 F) Operation
4. GENERAL DRIVING CYCLE

Perform the diagnosis continuously 6 seconds after engine start while variable valve lift is being controlled
5. DIAGNOSTIC METHOD
Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Low Duty ratio Variable valve lift diagnosis oil pressure switch High Duty ratio Variable valve lift diagnosis oil pressure switch Threshold Value t 62 % OFF
< 33 % ON
Time Needed for Diagnosis: Low side: 784 ms High side: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Low Duty ratio Variable valve lift diagnosis oil pressure switch High Duty ratio Variable valve lift diagnosis oil pressure switch Threshold Value t 62 % ON
< 33 % OFF
Time Needed for Diagnosis: Low side: 208 ms High side: 3000 ms
GD(H4SO)-9

GENERAL DESCRIPTION
B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 2)
NOTE: For the detection standard, refer to DTC P0026. <Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-10

GENERAL DESCRIPTION
C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

Detect functional errors of the front oxygen (A/F) sensor heater. Judge as NG when it is determined that the front oxygen (A/F) sensor impedance is large when looking at engine status such as deceleration fuel cut.
(1)
(2)
(4)
(3)
EN-02181
(1) (2)
Gasket Ceramic heater
(3)
Sensor housing
(4)
Protection tube
3. ENABLE CONDITION
Secondary Parameters Condition established time Battery voltage Heater current Control duty t 35 % After fuel cut Enable Conditions t 42000 ms t 10.9 V Permitted Experienced t 20000 ms

Perform the diagnosis continuously after 42000 ms or more have passed since the engine started.
GD(H4SO)-11

GENERAL DESCRIPTION
Malfunction Criteria Front oxygen (A/F) sensor impedance Threshold Value > 50 :
Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Front oxygen (A/F) sensor impedance Threshold Value d 50 :
Time Needed for Diagnosis: 10000 ms
GD(H4SO)-12

GENERAL DESCRIPTION
D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.
(A) OFF (B)
ON 0V
(D)
(C)
EN-01792
(A) (B)
Battery voltage Front oxygen (A/F) sensor heater output voltage
(C)
128 milliseconds
(D)
Low error
3. ENABLE CONDITION
Secondary Parameters Battery voltage Enable Conditions t 10.9 V

Always perform the diagnosis continuously.
GD(H4SO)-13

GENERAL DESCRIPTION
Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty Threshold Value Low < 87.5 %
Time Needed for Diagnosis:4 ms 250 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Output voltage level Threshold Value High
Time Needed for Diagnosis: Less than 1 second
GD(H4SO)-14

GENERAL DESCRIPTION
E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.
(A) (D) (B) OFF
ON 0V
(C)
EN-01793
(A) (B)
(C)
128 milliseconds
(D)
High error
3. ENABLE CONDITION

GD(H4SO)-15

GENERAL DESCRIPTION
Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty Threshold Value High t 12.5 %
Malfunction Criteria Output voltage level Threshold Value Low
GD(H4SO)-16

GENERAL DESCRIPTION

Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.
(A) OFF (B)
ON 0V
(D)
(C)
EN-01792
(A) (B)
Battery voltage Output voltage of the rear oxygen sensor heater
(C)
256 milliseconds (cycles)
(D)
Low error
3. ENABLE CONDITION
Secondary Parameters Battery voltage Elapsed time after engine starting Engine speed Enable Conditions t 10.9 V t 1 second < 8000 rpm

After starting the engine, perform the diagnosis continuously when engine is low speed.
GD(H4SO)-17

GENERAL DESCRIPTION
Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty Threshold Value Low < 75 %
Time Needed for Diagnosis:8 ms 320 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
GD(H4SO)-18

GENERAL DESCRIPTION

Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.
(A) (D) (B) OFF
ON 0V
(C)
EN-01793
(A) (B)
(C)
(D)
High error
3. ENABLE CONDITION

GD(H4SO)-19

GENERAL DESCRIPTION
Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty Threshold Value High t 20 %
GD(H4SO)-20

GENERAL DESCRIPTION
H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

Detect problems in the intake manifold pressure sensor output properties. Judge as NG when the intake air pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition, or when it is High whereas it seemed to be Low from the engine condition.
(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
Output voltage Connector
(B) (2)
Absolute pressure Terminals (3) O-ring
3. ENABLE CONDITION
Secondary Parameters Engine coolant temperature Enable Conditions t 75 C (167 F)

Perform the diagnosis continuously after idling.
GD(H4SO)-21

GENERAL DESCRIPTION
Abnormality Judgement Judge as NG when Low side or High side becomes NG. If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load Threshold Value < 2500 rpm t 12 < 1.63 V > 0.6 g/rev (0.02 oz/rev) 600 rpm 900 rpm < 2.44 t 3.4 V < 0.4 g/rev (0.01 oz/rev)
Time Needed for Diagnosis: Low side: 3000 ms High side: 7000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG when both Low side and High side become OK. If the duration of time while the following conditions are met is longer than the time indicated, judge as OK. Judgement Value
Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load Threshold Value < 2500 rpm t 12 t 1.63 V > 0.6 g/rev (0.02 oz/rev) 600 rpm 900 rpm < 2.44 < 3.4 V < 0.4 g/rev (0.01 oz/rev)
Time Needed for Diagnosis: Low side: Less than 1 second High side: Less than 1 second
GD(H4SO)-22

GENERAL DESCRIPTION
I:
DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)
Detect the open circuit of the oil switching solenoid valve. Judge as NG when the current is small even though the output duty is large.
2. ENABLE CONDITION

Malfunction Criteria Duty ratio Control current Threshold Value t 30 % < 0.026 A
Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria |Oil switching solenoid valve target current value Oil switching solenoid valve current value| Target current Threshold Value < 0.08 A
t 0.11 A
GD(H4SO)-23

GENERAL DESCRIPTION
J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)

Detect short circuits of the oil switching solenoid valve. Judge as a short NG when the current is large even though the output duty is small.
2. ENABLE CONDITION

Malfunction Criteria Duty ratio Control current Threshold Value <7% t 0.465 A
Malfunction Criteria |Oil switching solenoid valve target current value Oil switching solenoid valve current value| Threshold Value < 0.08 A
GD(H4SO)-24

GENERAL DESCRIPTION
K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)

NOTE: For the detection standard, refer to DTC P0076. <Ref. to GD(H4SO)-23, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)

NOTE: For the detection standard, refer to DTC P0077. <Ref. to GD(H4SO)-24, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-25

GENERAL DESCRIPTION
M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

Detect the malfunction of air flow sensor output properties. Judge as a low side NG when the air flow voltage indicates a small value regardless of running in a state where the air flow voltage increases. Judge as a high side NG when the air flow voltage indicates a large value regardless of running in a state where the air flow voltage decreases. Judge air flow sensor property NG when the Low side or High side becomes NG.
(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
Air Air flow sensor Intake air temperature sensor (3) Voltage (V) (4) Amount of intake air (kg (lb)/s)
3. ENABLE CONDITION

GD(H4SO)-26

GENERAL DESCRIPTION
Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High (1) Output voltage Engine speed Throttle opening angle Intake manifold pressure High (2) Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis Threshold Value < 1.49 V t 2000 rpm t 12 t 66.7 kPa (500 mmHg, 19.7 inHg) t 2.66 V 600 rpm 900 rpm < 2.44 t 40 kPa (300 mmHg, 11.8 inHg) t 1.45 V 600 rpm 900 rpm < 2.44 t 40 kPa (300 mmHg, 11.8 inHg) Rich side malfunction
Time Needed for Diagnosis: Low: 5000 ms High: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG when both Low side and High side become OK. Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis Threshold Value t 1.49 V t 2000 rpm t 12 t 66.7 kPa (500 mmHg, 19.7 inHg) < 2.66 V 600 rpm 900 rpm < 2.44 < 40 kPa (300 mmHg, 11.8 inHg) Rich side normal
Time Needed for Diagnosis: Low: Less than 1 second High: Less than 1 second
GD(H4SO)-27

GENERAL DESCRIPTION
N: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

Detect open or short circuits of the air flow sensor. Judge as NG if out of specification.
(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION
Secondary Parameters None Enable Conditions

Malfunction Criteria Output voltage Threshold Value d 0.22 V
Malfunction Criteria Output voltage Threshold Value > 0.22 V
GD(H4SO)-28

GENERAL DESCRIPTION
O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION

Malfunction Criteria Output voltage Threshold Value t 4.179943192 V
Malfunction Criteria Output voltage Threshold Value < 4.179943192 V
GD(H4SO)-29

GENERAL DESCRIPTION
P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT

Detect the open or short circuit of intake manifold pressure sensor. Judge as NG if out of specification.
(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4SO)-30

GENERAL DESCRIPTION
Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT

(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4SO)-31

GENERAL DESCRIPTION
R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/ PERFORMANCE

Detect the malfunction of intake air temperature sensor output property. Judge as NG when the intake air temperature is not varied whereas it seemed to be varied from the viewpoint of engine condition.
(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
Air Air flow sensor Intake air temperature sensor (3) Resistance value (:) (4) Intake air temperature C (F)
3. ENABLE CONDITION
Secondary Parameters Engine coolant temperature at engine starting Engine coolant temperature Battery voltage Continuous time when the vehicle speed is less than 60 km/h (37.3 MPH) Enable Conditions < 30 C (86 F) t 100 C (212 F) t 10.9 V t 600 s

Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition.
GD(H4SO)-32

GENERAL DESCRIPTION
Abnormality Judgement Judge as NG when the following conditions are established. Judgement Value
Malfunction Criteria Output voltage difference between Max. and Min. Threshold Value < 0.02 V(Equivalent to approximately 0.5C (0.9F) near 25C)
Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria Output voltage difference between Max. and Min. Threshold Value t 0.02 V
GD(H4SO)-33

GENERAL DESCRIPTION
S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

Detect open or short circuit of the intake air temperature sensor. Judge as NG if out of specification.
(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION

GD(H4SO)-34

GENERAL DESCRIPTION
T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION

GD(H4SO)-35

GENERAL DESCRIPTION
U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

Detect the open or short circuit of the engine coolant temperature sensor. Judge as NG if out of specification.
(1)
(A)
(B)
(2) EN-02917
(A) (1)
Resistance value (k:) Connector
(B) (2)
Temperature C (F) Thermistor element
3. ENABLE CONDITION

GD(H4SO)-36

GENERAL DESCRIPTION
V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4SO)-37

GENERAL DESCRIPTION
W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW

Detect the open or short circuit of throttle position sensor 1. Judge as NG if out of specification.
(3) (4)
(1)
(2)
EN-01859
(1) (2)
Throttle position sensor 1 signal Throttle position sensor 2 signal
(3)
Throttle position sensor
(4)
Engine control module (ECM)
3. ENABLE CONDITION
Secondary Parameters Ignition switch Battery voltage Enable Conditions ON t6V

Malfunction Criteria Sensor 1 input voltage Threshold Value d 0.217 V
Malfunction Criteria Sensor 1 input voltage Threshold Value > 0.217 V
GD(H4SO)-38

GENERAL DESCRIPTION
X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

Malfunction Criteria Sensor 1 input voltage Threshold Value t 4.858 V
Malfunction Criteria Sensor 1 input voltage Threshold Value < 4.858 V
GD(H4SO)-39

GENERAL DESCRIPTION
Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
Detect the malfunction of engine coolant temperature output property. Judge as NG when the engine coolant temperature does not rise in driving conditions where it should.
(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION
Secondary Parameters Engine speed Battery voltage Enable Conditions t Value from Map t 10.9 V
Map
Engine coolant temperature C (F) Engine speed rpm Engine coolant temperature C (F) Engine speed rpm 40 (40) 500 30 (22) 500 20 (4) 500 10 (14) 500 0 (32) 500 10 (50) 500 20 (68) 500 30 (86) 500
40 (104) 500
50 (122) 500
60 (140) 500
70 (158) 500
80 (176) 500
90 (194) 500
100 (212) 500
110 (230) 500

Perform the diagnosis only once after engine start.
GD(H4SO)-40

GENERAL DESCRIPTION
Abnormality Judgement Judge as NG if the criteria below are met. Judgement Value
Malfunction Criteria Engine coolant temperature Timer for diagnosis after engine start Threshold Value < 20 C (68 F) t Judgement value of timer after engine start
Timer for diagnosis after engine start a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 milliseconds + TWCNT milliseconds (the time of at 64 milliseconds) TWCNT is defined as follows, TWCNT = 0 at idle switch ON, TWCNT show on the following table at idle switch OFF.
0 (0) 20 (4) 10 (14) Temperature 0 (32) C (F) 10 (50) 20 (68) 0 ms 0 ms 0 ms 0 ms 0 ms 8 (5) 32.076 ms 25.704 ms 17.646 ms 7.901 ms 7.901 ms 16 (9.9) 39.977 ms 33.606 ms 25.548 ms 15.802 ms 15.802 ms Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 40 (24.9) 47.879 ms 41.508 ms 33.45 ms 23.704 ms 23.704 ms 82.544 ms 117.209 ms 68.52 ms 95.532 ms 53.652 ms 73.855 ms 37.941 ms 52.177 ms 37.941 ms 52.177 ms 48 (29.8) 154.214 ms 125.667 ms 97.12 ms 68.573 ms 68.573 ms 56 (34.8) 185.26 ms 155.802 ms 120.386 ms 82.538 ms 82.538 ms
Judgement value of timer after engine starting t = 573669 ms 33924 ms Ti Ti : The lowest coolant temperature after engine start Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG when the malfunction criteria below are met. Judgement Value
Malfunction Criteria Engine coolant temperature Threshold Value t 20 C (68 F)
GD(H4SO)-41

GENERAL DESCRIPTION
Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION

Detect the malfunction of the engine coolant temperature sensor characteristics. Memorize the engine coolant temperature and fuel temperature at the last engine stop, and use them to judge as NG when the engine coolant temperature does not decrease when it should.
(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION
Secondary Parameters Battery voltage Refueling from the last engine stop till the current engine start Fuel level Engine coolant temperature at the last engine stop Enable Conditions t 10.9 V None t 15 2 (3.96 US gal, 3.3 Imp gal) t 75 C (167 F)

Perform the diagnosis only once after starting the engine.
GD(H4SO)-42

GENERAL DESCRIPTION
Malfunction Criteria Engine coolant temperature at the last engine stop Minimum engine coolant temperature after the engine start Fuel temperature at the last engine stop fuel temperature Intake air temperature fuel temperature Fuel temperature Threshold Value < 2.5 C (36.5 F)
t 5 C (41 F) < 2.5 C (36.5 F) < 35 C (95 F)
Malfunction Criteria Engine coolant temperature at the last engine stop Minimum engine coolant temperature after the engine start Threshold Value t 2.5 C (36.5 F)
GD(H4SO)-43

GENERAL DESCRIPTION
AA:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
Detect malfunctions of the thermostat function. Judge as NG when the engine coolant temperature is lower than the estimated engine coolant temperature and the difference between them is large. Judge as OK when the engine coolant temperature becomes to 75C (167F), and the difference is small, before judging NG.
(8)
(2)
(2)
(7)
(6)
(5)
(9)
(4) (3)
(1)
EN-01692
(1) (2) (3)
Valve Spring Stopper
(4) (5) (6)
Piston Guide Rubber seal
(7) (8) (9)
Stop ring Wax element Jiggle valve
3. ENABLE CONDITION

GD(H4SO)-44

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Estimated coolant temperature Engine coolant temperature (Estimated Measured) Engine coolant temperature Vehicle speed Threshold Value t 10.9 V t 7 C (19.4 F) Incomplete < 55 C (131 F) t 75 C (167 F) d 75 C (167 F) > 30 C (86 F) t 30 km/h (18.6 MPH)
Time Needed for Diagnosis:64 ms 3 time(s) 152 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Engine coolant temperature (Estimated Measured) Engine coolant temperature Threshold Value t 10.9 V t 7 C (19.4 F) Incomplete < 55 C (131 F) t 75 C (167 F) d 30 C (86 F)
GD(H4SO)-45

GENERAL DESCRIPTION
AB:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
Electromotive force Air fuel ratio Atmosphere Exhaust gas
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H4SO)-46

GENERAL DESCRIPTION
Malfunction Criteria Input voltage (+) or Input voltage () or |Input voltage (+) Input voltage ()| Threshold Value < 1.128 V < 0.23 V < 0.644 V
Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (): 1000 ms |Input voltage (+) Input voltage ()|: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Input voltage (+) Input voltage () |Input voltage (+) Input voltage ()| Threshold Value t 1.128 V t 0.23 V t 0.644 V
GD(H4SO)-47

GENERAL DESCRIPTION
AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H4SO)-48

GENERAL DESCRIPTION
Malfunction Criteria Input voltage (+) or Input voltage () Threshold Value > 3.589 V > 3.541 V
Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (): 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Input voltage (+) Input voltage () Threshold Value d 3.589 V d 3.541 V
GD(H4SO)-49

GENERAL DESCRIPTION
AD:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

Detect the slow response of front oxygen (A/F) sensor. Front oxygen (A/F) sensor cover has some ventilation holes for exhaust gas. Clogged ventilation holes are diagnosed. When the holes are clogged, the A/F output variation becomes slow comparing with the actual A/F variation because oxygen which reaches the zirconia layer is insufficient. Therefore, if the sensor cover holes are clogged, the rich to lean judgment in the ECM is delayed when the actual change from rich to lean occurs. Judge as NG when the actual movement in comparison to the ECM control amount is slow.
(2) (1)
(3)
EN-01694
(1)
Cover
(2)
Zirconia
(3)
Clogging
GD(H4SO)-50

GENERAL DESCRIPTION
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION
Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Closed loop control with main feedback Front oxygen (A/F) sensor impedance Elapsed time after starting the engine Engine coolant temperature Engine speed Vehicle speed Amount of intake air Engine load Learning value of EVAP conc. during purge Total time of operating canister purge Enable Conditions t 1024 ms t 10.9 V > 75 kPa (563 mmHg, 22.2 inHg) Operation 0 : 50 : t 120000 ms t 75 C (167 F) 1000 rpm 3200 rpm 10 km/h 120 km/h (6.2 MPH 74.6 MPH) 10 g/s 40 g/s (0.35 oz/s 1.41 oz/s) < 0.02 g/rev (0 oz/rev) < 0.2 t 19.9 s

Perform diagnosis only once at a constant speed of 10 km/h 120 km/h (6.2 MPH 74.6 MPH) 120000 ms or more after starting the engine.
GD(H4SO)-51

GENERAL DESCRIPTION
Calculate faf difference every 32ms 4 , and the O value difference. Calculate the diagnosis value after calculating 1640 time(s). Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n1) + |d2faf (n)| td2lmd (N) = td2lmd (n1) + |d2lmd (n)| add up to 32 ms 4 1640 time(s). d2faf (n) = (faf (n) faf (n1)) (faf (n1) faf (n2)) d2lmd (n) = (lmd (n) lmd (n1)) (lmd (n1) lmd (n2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds Threshold Value > 0.4 (U5 model) > 0.45 (Other than U5 model)
Time Needed for Diagnosis: 32 ms 4 1640 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n1) + |d2faf (n)| td2lmd (N) = td2lmd (n1) + |d2lmd (n)| add up to 32 ms 4 1640 time(s). d2faf (n) = (faf (n) faf (n1)) (faf (n1) faf (n2)) d2lmd (n) = (lmd (n) lmd (n1)) (lmd (n1) lmd (n2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds Threshold Value d 0.4 (U5 model) d 0.45 (Other than U5 model)
Time Needed for Diagnosis: 32 ms 4 1640 time(s)
GD(H4SO)-52

GENERAL DESCRIPTION
AE:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

Detect open circuits of the sensor. Judge as NG when the impedance of the element is large.
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H4SO)-53

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Time of heater control duty at 70 % or more Front oxygen (A/F) sensor impedance. Threshold Value t 10.9 V t 36000 ms > 500 :
Malfunction Criteria Battery voltage Front oxygen (A/F) sensor impedance. Threshold Value t 10.9 V d 500 :
GD(H4SO)-54

GENERAL DESCRIPTION
AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

Detect continuity NG of the oxygen sensor. If the oxygen sensor voltage reading is not within the probable range considering the operating conditions, judge as NG.
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
Electromotive force Air fuel ratio Atmosphere
(C) (D) (2)
Rich Lean Exhaust gas
(E) (F) (3)
Theoretical air fuel ratio Comparative voltage Electromotive force
GD(H4SO)-55

GENERAL DESCRIPTION
3. ENABLE CONDITION
Used for abnormality judgment
Secondary Parameters High Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Low (1) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Low (2) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Low (3) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Fuel cut Enable Conditions Not in operation In operation < 5 time(s) Not in limit value t 10.9 V t 75 C (167 F) Not in operation In operation < 5 time(s) Not in limit value t 10.9 V t 75 C (167 F) t 10 g/s (0.35 oz/s) Not in operation In operation < 5 time(s) Not in limit value t 10.9 V t 75 C (167 F) < 10 g/s (0.35 oz/s) t 30000 ms
Not in operation In operation < 5 time(s) Not in limit value t 10.9 V t 75 C (167 F) < 10 g/s (0.35 oz/s) t 30000 ms Experienced
Used for normality judgment

Secondary Parameters Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Enable Conditions Not in operation In operation < 5 time(s) Not in limit value t 10.9 V t 75 C (167 F)
GD(H4SO)-56

GENERAL DESCRIPTION

After starting the engine, continuously perform the diagnosis with the same engine condition.
Malfunction Criteria High Sensor output voltage Low Sensor output voltage Threshold Value P0138 > 1.2 V P0137 < 0.03 V DTC
Time Needed for Diagnosis: High: 2500 ms Low (1): 20000 ms Low (2): 40000 ms Low (3): Value from Map Map
Fuel Cut Time (millisecond) Time needed for diagnosis (millisecond) 0 40000 2000 40000 10000 60000
Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria High Sensor output voltage Low Sensor output voltage Threshold Value P0138 d 1.2 V P0137 t 0.03 V DTC
Time Needed for Diagnosis: High: Less than 1 second Low (1): Less than 1 second Low (2): Less than 1 second Low (3): Less than 1 second
AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

NOTE: For the detection standard, refer to DTC P0137. <Ref. to GD(H4SO)-55, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-57

GENERAL DESCRIPTION
AH:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

Detect the slow response of the oxygen sensor. Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and Judge as OK if both are OK. [Rich o lean diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean. If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK. 2. Judge as NG when the oxygen sensor voltage is large (rich) when recovering from a deceleration fuel cut. [Lean o rich diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich. If the measured response time is larger than the threshold value, it is NG. 2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel cut. Diagnostic method Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to lean. And Judge as NG when the measured response time is larger than the threshold value.
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION
Rich o lean diagnosis response
Enable Conditions Battery voltage t 10.9 V A/F main feedback control condition Completed Deceleration fuel cut time is 6000 ms or more. Experienced After fuel cut t 2000 ms Current calculation time of the rear oxygen sensor heater t 60000 ms Current continuation time of the rear oxygen sensor heater t 30000 ms Estimated catalyst temperature t 480 C (896 F) Number of deceleration fuel cut t 1 time(s) Secondary Parameters
GD(H4SO)-58

GENERAL DESCRIPTION

Perform the diagnosis only once when deceleration fuel cut occurs after rapid acceleration. (Pay attention to the oxygen sensor voltage for the timing of the deceleration.)
When the oxygen sensor output voltage changes from 0.55 V (rich) to 0.15 V (lean), calculate the minimum response time for output change between 0.5 V and 0.2 V for the judgment criteria.
Diagnosis execution condition
(A) (B)
Rear oxygen sensor (V) (G) (C) (D) (E)
Fuel cut on deceleration (F) (H)
EN-05566
(A) (B) (C) (D)
0.55 V 0.5 V 0.2 V 0.15 V
(E) (F) (G)
0V More than 6000 ms Measure the response time.
(H)
Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.
GD(H4SO)-59

GENERAL DESCRIPTION
Abnormality Judgement 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value o abnormal NOTE: Variation time of rear oxygen sensor output voltage is short during fuel cut in deceleration. NG judgment should be performed after deceleration fuel cut. Even without deceleration fuel cut, judge as OK if the value is below the threshold. When the deceleration fuel cut time is 6000 ms or more, judge as NG if the following criteria are met 2000 ms after recovering from the deceleration fuel cut. 2) Judge as NG when the oxygen sensor voltage at recovery from a deceleration fuel cut, is large. If the fuel cut time in a deceleration fuel cut is long (6000 ms or more), and even after recovering from a deceleration fuel cut, the oxygen sensor voltage is high (0.55 V or more), judge as NG. Judgement Value
Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V or Longest time over 0.55 V Threshold Value > 491 ms
t 2000 ms
Time Needed for Diagnosis: 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement 1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal condition. Response time (diagnosis value) d threshold value o normal 2) Do not judge as a normal condition.
Judge as OK and clear the NG if the following conditions are established.
Judgement Value
Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V Threshold Value d 491 ms
Time Needed for Diagnosis: 1 time(s)
6. ENABLE CONDITION
Lean o rich response diagnosis
Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time is 6000 ms or more. After fuel cut Current calculation time of the rear oxygen sensor heater Current continuation time of the rear oxygen sensor heater Estimated catalyst temperature Number of deceleration fuel cut Enable Conditions t 10.9 V Complete Experienced t 2000 ms t 60000 ms t 30000 ms t 450 C (842 F) t 1 time(s)
GD(H4SO)-60

GENERAL DESCRIPTION

When the oxygen sensor output voltage changes from 0.25 V (lean) to 0.55 V (rich), calculate the minimum response time for output change between 0.3 V and 0.5 V for the judgment criteria.
(H)
(A) (B)
Rear oxygen sensor (V)
(C) (D) (E)
(J)
(G) Fuel cut on deceleration (F) (I)
EN-05567
(A) (B) (C) (D) (E) (F)
0.55 V 0.5 V 0.3 V 0.25 V 0V More than 5 seconds
(G) (H) (I)
More than 120000 ms Measure the response time (diagnostic value). Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.
(J)
Judge NG when the voltage of rear oxygen sensor is 0.25 V or less for 120000 ms or more after recovery of fuel cut on deceleration.
GD(H4SO)-61

GENERAL DESCRIPTION
Abnormality Judgement 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value o abnormal 2) If the oxygen sensor voltage is small after recovering from a deceleration fuel cut, and remains small, judge as NG. Judgement Value
Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V or Longest time under 0.25 V Threshold Value > 2000 ms
t 120000 ms
Judgement Value
Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V Threshold Value d 2000 ms
GD(H4SO)-62

GENERAL DESCRIPTION
AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)

Detect the rear oxygen sensor open or short circuit. Judge as NG when the rear oxygen sensor voltage can be determined to be abnormal considering conditions such as intake air amount, engine coolant temperature, main feedback control and deceleration fuel cut.
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT)

Secondary Parameters Closed loop control at the rear oxygen sensor Target output voltage of rear oxygen sensor Amount of intake air Engine coolant temperature Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Deceleration fuel cut of 6000 ms or more. Enable Conditions In operation t 0.55 V + 0.05 V t 10 g/s (0.35 oz/s) t 75 C (167 F) < 5 time(s) Not in limit value t 10.9 V Experienced

Perform the diagnosis once after starting the engine.
GD(H4SO)-63

GENERAL DESCRIPTION
Malfunction Criteria Minimum output voltage or Maximum output voltage Threshold Value > 0.15 V < 0.55 V
Time Needed for Diagnosis: 200000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria Threshold Value Diagnosis of the rear oxygen sensor volt- Incomplete age low side Minimum output voltage d 0.15 V Maximum output voltage t 0.55 V
GD(H4SO)-64

GENERAL DESCRIPTION
AJ:DTC P0171 SYSTEM TOO LEAN (BANK 1)

Detect fuel system malfunction by the amount of main feedback control. Diagnostic method Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.
2. ENABLE CONDITION
Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Engine load Enable Conditions In operation t 75 C (167 F) < 0.02 g/rev (0 oz/rev) t Value of Map 1
Map1
Engine speed (rpm) Measured value (g(oz)/rev) Idling Non-turbo 650 0.208 (0.01) 1000 0.201 (0.01) 1500 0.185 (0.01) 2000 0.183 (0.01) 2500 0.193 (0.01) 3000 0.206 (0.01) 3500 0.206 (0.01) 4000 0.225 (0.01) 4500 0.245 (0.01)

Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.
Abnormality Judgement Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction criteria below continues for 10 s 5 time(s) or more, judge that there is a fault in the fuel system. Judgement Value
Malfunction Criteria fsobd = (sglmd tglmda) + faf + flaf In this case: sglmd = measured lambda tglmda = target lambda faf = main feedback compensation coefficient every 64 milliseconds flaf = main feedback learning compensation coefficient Threshold Value t Value of Map 2
Map2 U5 MODEL
Amount of air (g (oz)/s) fsobdL1 (%) 0 (0) 1.4 3.2 (0.11) 1.4 6.4 (0.23) 1.332 9.6 (0.34) 1.25 12.8 (0.45) 1.25 16 (0.56) 1.25 19.2 (0.68) 1.25
EXCEPT FOR U5 MODEL

Time Needed for Diagnosis: 10 s 5 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4SO)-65

GENERAL DESCRIPTION
Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria fsobd = (sglmd tglmda) + faf + flaf Threshold Value < 1.2
Time Needed for Diagnosis: 10 s
GD(H4SO)-66

GENERAL DESCRIPTION
AK:DTC P0172 SYSTEM TOO RICH (BANK 1)

2. ENABLE CONDITION
Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Learning value of EVAP conc. Cumulative time of canister purge after engine start Continuous period after canister purge starting Engine load Enable Conditions In operation t 75 C (167 F) d 0.02 g/rev (0 oz/rev) < 0.15 t 20 s t 29884 ms t Value of Map 1
Map1
Engine speed (rpm) Measured value (g(oz)/rev) Idling Non-turbo 650 0.208 (0.01) 1000 0.201 (0.01) 1500 0.185 (0.01) 2000 0.183 (0.01) 2500 0.193 (0.01) 3000 0.206 (0.01) 3500 0.206 (0.01) 4000 0.225 (0.01) 4500 0.245 (0.01)

Malfunction Criteria Threshold Value fsobd = (sglmd tglmda) + faf + flaf < Value of Map 2 In this case: sglmd = measured lambda tglmda = target lambda faf = main feedback compensation coefficient every 64 milliseconds flaf = main feedback learning compensation coefficient
Map2
Time Needed for Diagnosis: 10 s 5 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK when the malfunction criteria below continues for 10 seconds. Judgement Value
Malfunction Criteria fsobd = (sglmd tglmda) + faf + flaf Threshold Value t 0.8
GD(H4SO)-67

GENERAL DESCRIPTION
AL:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/ PERFORMANCE

Detect faults in the fuel temperature sensor output properties. Diagnosis is performed in two methods (drift diagnosis and stuck diagnosis). If either is NG, judge as NG. If both are OK, Judge as OK and clear the NG. Drift Diagnosis Normally fuel temperature is lower than engine coolant temperature. When the fuel temperature becomes higher than the engine coolant temperature, the range is considered to be shifted, and judged as NG. Stuck Diagnosis As the engine warms up (cumulative amount of intake air after starting is large), if the fuel temperature which should rise does not, determine as being stuck and NG.
(A)
(B)
EN-01700
(A)
Resistance value (:)
(B)
Fuel temperature C (F)
3. ENABLE CONDITION
DRIFT DIAGNOSIS

GD(H4SO)-68

GENERAL DESCRIPTION
Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature Engine coolant temperature at engine start Fuel temperature Engine coolant temperature Battery voltage Threshold Value t 9.6 2 (2.54 US gal, 2.11 Imp gal) t 20 s > 10 C (50 F) t 10 C (50 F) t 10.9 V
Time Needed for Diagnosis: 120 s Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature Engine coolant temperature at engine start Fuel temperature Engine coolant temperature Battery voltage Engine coolant temperature Threshold Value t 9.6 2 (2.54 US gal, 2.11 Imp gal) t 20 s > 10 C (50 F) < 10 C (50 F) t 10.9 V < 75 C (167 F)
6. ENABLE CONDITION
Stuck Diagnosis
Secondary Parameters Elapsed time after starting the engine Battery voltage Enable Conditions t 20000 ms t 10.9 V
GD(H4SO)-69

GENERAL DESCRIPTION

Always perform diagnosis after 20 seconds have passed since the engine started.
Malfunction Criteria Accumulated amount of intake air Fuel temperature difference between Max. and Min. Threshold Value t 551043 g (19435.29 oz) < 2 C (35.6 F)
Malfunction Criteria Fuel temperature difference between Max. and Min. Threshold Value t 2 C (35.6 F)
GD(H4SO)-70

GENERAL DESCRIPTION
AM:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

Detect the open or short circuit of fuel temperature sensor. Judge as NG if out of specification.
(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION

Malfunction Criteria Output voltage Battery voltage Threshold Value < 0.343951474 V t 10.9 V
Malfunction Criteria Output voltage Battery voltage Threshold Value t 0.343951474 V t 10.9 V
GD(H4SO)-71

GENERAL DESCRIPTION
AN:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION

Time Needed for Diagnosis: Within 1 second
GD(H4SO)-72

GENERAL DESCRIPTION
AO:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE

Detect for abnormal values in the oil temperature sensor output properties. Judge as NG when the oil temperature does not rise even though the engine is running under a condition where it should rise.
2. ENABLE CONDITION
Secondary Parameters Battery voltage Engine speed Enable Conditions t 10.9 V t Value from Map
Map
Engine coolant temperature C (F) Engine speed rpm Engine coolant temperature C (F) Engine speed rpm 40 (40) 500 30 (22) 500 20 (4) 500 10 (14) 500 0 (32) 500 10 (50) 500 20 (68) 500 30 (86) 500
40 (104) 500
50 (122) 500
60 (140) 500
70 (158) 500
80 (176) 500
90 (194) 500
100 (212) 500
110 (230) 500

Perform the diagnosis continuously after starting the engine.
GD(H4SO)-73

GENERAL DESCRIPTION
Malfunction Criteria Engine oil temperature After engine start oil temperature sensor characteristic diagnosis timer. Threshold Value < 15 C (59 F) t Judgement value for after engine start oil temperature sensor characteristic diagnosis timer
After engine start oil temperature sensor characteristic diagnosis timer (timer for diagnosis). a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 milliseconds + TOILCNT milliseconds (at the time of 64 milliseconds). Where, TOILCNT is determined as follows, TOILCNT = 0 at idle switch ON For TOILCNT at Idle switch off, refer to the following table.
0 (0) 64 ms 64 ms 64 ms 64 ms 102.2 ms 8 (5) 73.2 ms 73.3 ms 73.4 ms 73.5 ms 114.8 ms 16 (9.9) 83.9 ms 84 ms 84.2 ms 84.5 ms 129.4 ms Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 96.3 ms 113.2 ms 96.6 ms 113.7 ms 96.9 ms 114.5 ms 97.4 ms 115.6 ms 146.7 ms 171.7 ms 40 (24.9) 133.9 ms 135 ms 136.4 ms 138.5 ms 203.4 ms 48 (29.8) 160.2 ms 162 ms 164.4 ms 168 ms 245.1 ms 56 (34.8) 194.6 ms 197.4 ms 201.5 ms 207.6 ms 302.1 ms
30 (22) 20 (4) Temperature 10 (14) C (F) 0 (32) 10 (50)
After engine start oil temperature characteristic diagnosis timer judgment value (t). t = 1882940 ms 43302 ms Ti (t t 2400000) Ti = The lowest coolant temperature after starting the engine. Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria Engine oil temperature Threshold Value t 15 C (59 F)
GD(H4SO)-74

GENERAL DESCRIPTION
AP:DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW

Detect the open or short circuit of the oil temperature sensor. Judge as NG when outside of the judgment value.
2. ENABLE CONDITION

GD(H4SO)-75

GENERAL DESCRIPTION
AQ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH

2. ENABLE CONDITION

GD(H4SO)-76

GENERAL DESCRIPTION
AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4SO)-77

GENERAL DESCRIPTION
AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4SO)-78

GENERAL DESCRIPTION

Detect the presence of misfire occurrence. (Revolution fluctuation method) Monitoring Misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made obligatory by the law. Misfire affecting these two has two patterns below. : Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.) : FTP 1.5 times misfire Every time misfire (The same cylinder misfires every time.) : FTP 1.5 times misfire, Catalyst damage misfire The following detecting methods are adopted for these detection. 1) Intermittent misfire: FTP 1.5 times misfire 180 Interval Difference Method (MT: 1,800 rpm or less; AT: None) 360 Interval Difference Method (whole range) 720 Interval Difference Method (3,000 rpm or more) 2) Misfire every time: FTP 1.5 times misfire, Catalyst damage misfire 360 Interval Difference Method
2. ENABLE CONDITION
Secondary Parameters All secondary parameters enable conditions Intake manifold pressure change at 180CA Throttle position change during 16 milliseconds Fuel shut-off function Fuel level Vehicle dynamic control or AT torque control Evaporative system leak check Engine speed Intake manifold pressure Battery voltage Fuel parameter determination Elapsed time after starting the engine Engine load change during 32 milliseconds Enable Conditions t 1024 ms < Value of Map 1 < 21 Not in operation t 9.6 2 (2.54 US gal, 2.11 Imp gal) Not in operation Not in operation 460 rpm 6300 rpm t Value from Map 2 t8V Not extremely low volatility t 0 ms < 1000 rpm
GD(H4SO)-79

GENERAL DESCRIPTION
Map1 AT model
rpm kPa (mmHg, inHg) 700 13.3 (100, 3.9) 1000 13.3 (100, 3.9) 1500 13.3 (100, 3.9) 2000 13.3 (100, 3.9) 2500 13.3 (100, 3.9) 3000 13.3 (100, 3.9) 3500 13.3 (100, 3.9) 4000 13.3 (100, 3.9) 4500 13.3 (100, 3.9) 5000 13.3 (100, 3.9) 5500 13.3 (100, 3.9) 6000 13.3 (100, 3.9) 6300 13.3 (100, 3.9)
MT model
rpm kPa (mmHg, inHg) 650 13.3 (100, 3.9) 1000 13.3 (100, 3.9) 1500 13.3 (100, 3.9) 2000 13.3 (100, 3.9) 2500 13.3 (100, 3.9) 3000 13.3 (100, 3.9) 3500 13.3 (100, 3.9) 4000 13.3 (100, 3.9) 4500 13.3 (100, 3.9) 5000 13.3 (100, 3.9) 5500 13.3 (100, 3.9) 6000 13.3 (100, 3.9) 6300 13.3 (100, 3.9)
Map2 AT model
rpm kPa (mmHg, inHg) 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300 23.6 25.1 26.2 26.6 26.9 30 33.4 37.8 39.5 23.1 26 23.9 23.3 (195.0, (179.5, (174.7, (173.2, (176.8, (188.0, (196.9, (199.6, (201.5, (225.0, (250.4, (283.5, (296.0, 6.8) 7) 7.4) 7.8) 7.9) 7.9) 8.9) 9.9) 11.2) 11.7) 6.9) 7.1) 7.7)
MT model Vehicle speed < 64 km/h (39.8 MPH)

rpm kPa (mmHg, inHg) 650 24.5 (184, 7.2) 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 27.1 28.8 32.3 22.7 21.4 21.5 21.5 23.2 24.7 25.8 (170.3, (160.2, (161.6, (161.4, (174.4, (185.5, (193.3, (203.2, (216.3, (242.2, 6.7) 6.3) 6.4) 6.4) 6.9) 7.3) 7.6) 8) 8.5) 9.5) 6000 36.3 (272, 10.7) 6300 37.9 (284.5, 11.2)
Vehicle speed t 68 km/h (42.3 MPH)

rpm kPa (mmHg, inHg) 650 31.6 (237, 9.3) 1000 31.6 (237, 9.3) 1500 31.6 (237, 9.3) 2000 31.1 (233, 9.2) 2500 31.3 (235, 9.3) 3000 33.1 (248, 9.8) 3500 33.9 (254, 10) 4000 28.8 (216, 8.5) 4500 30.1 (226, 8.9) 5000 33.3 (250, 9.8) 5500 36.9 (277, 10.9) 6000 40.1 (301, 11.9) 6300 43.2 (324, 12.8)

If conditions are met, it is possible to detect the misfires from idling to high engine speed. However, to avoid excessive load or harm to the engine, perform diagnosis at idle. Perform the diagnosis continuously.
GD(H4SO)-80

GENERAL DESCRIPTION
When a misfire occurs, the engine speed will decreased and the crankshaft position speed will change. Calculate the interval difference value (diagnostic value) from crankshaft position speed by the following formula, and judge whether a misfire is occurring or not comparing the calculated result with judgment value. Counting the number of misfires. If the misfire ratio is higher during 1000 revs. or 200 revs., Judge corresponding cylinders as NG.
Diagnostic value calculation (Calculate from angle speed) o Misfire detection every single ignition (Compare diagnostic value with judgment value) o 180 Interval Difference Method 360 Interval Difference Method 720 Interval Difference Method NG judgment (Misfire occurrence judgment required by the law) (Compare number of misfire with judgment) FTP 1.5 times misfire NG judgment Catalyst damage misfire NG judgment
As shown in the following figure, pick a cylinder as the standard and name it omg 0. And the former crankshaft position speed is named omg 1, the second former crankshaft position speed is named omg 2, the third is named omg 3, etc.
(A)
#3
#2
#4
#1
#3
#2
#4
#1
#3
#2
(B)
omg7
omg6
omg5
omg4
omg3
omg2
omg1
omg0
EN-01774
(A)
Ignition order
(B)
Crankshaft position speed
GD(H4SO)-81

GENERAL DESCRIPTION
180 Interval Difference Method

Diagnostic value domg 180 = (omg 1 omg 0) (omg 5 omg 1)/4 Judge as a misfire in the following cases. domg 180 > judgment value of positive side domg 180 d judgment value of negative side (Judgement value before 180 CA)
domg180 Threshold valve (positive number)
domg180
Threshold valve (negative number)
Judged as misfire.
EN-02877

Diagnostic value Misfire judgment domg 360 = (omg 1 omg 0) (omg 3 omg 2) domg 360 > Judgement value o Judge as misfire
domg360 Threshold valve
domg360
Judged as misfire.
EN-03273
GD(H4SO)-82

GENERAL DESCRIPTION

Diagnostic value Misfire judgment domg 720 = (omg 1 omg 0) (omg 5 omg 4) domg 720 > Judgement value o Judge as misfire
domg720
Threshold valve
domg720
Judged as misfire.
EN-03274
FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas) Abnormality Judgement Judgement Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.)
Malfunction Criteria FTP emission judgment value Threshold Value t 18 100/2000% in 1000 revs. (U5 model) t 20 100/2000% in 1000 revs. (Except for U5 model)
Time Needed for Diagnosis: 1000 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judgement Value
Malfunction Criteria FTP emission judgment value Threshold Value < 18 100/2000% in 1000 revs. (U5 model) < 20 100/2000% in 1000 revs. (Except for U5 model)
Time Needed for Diagnosis: 1000 engine revs.
GD(H4SO)-83

GENERAL DESCRIPTION
Catalyst damage misfire (Misfire occurrence level damaging catalyst) Abnormality Judgement Judgement Value
Malfunction Criteria Catalyst damage misfire judgment value Threshold Value t Value of Map 3
Map 3 U5 MODEL
0.16 (0.01) 100 100 100 80 67 57 44 36 27 20 20 20 20 0.28 (0.01) 100 100 100 80 67 57 44 36 27 20 20 20 20 0.4 (0.01) 100 100 90 80 58 49 34 28 20 20 20 20 20 Intake air (g(oz)/rev) 0.52 (0.02) 0.64 (0.02) 100 90 100 90 80 69 80 62 50 40 40 30 24 20 20 20 20 20 20 20 20 20 20 20 20 20 0.76 (0.03) 80 80 57 44 31 20 20 20 20 20 20 20 20 0.92 (0.03) 64 52 39 33 25 20 20 20 20 20 20 20 20 1.1 (0.04) 48 24 22 21 20 20 20 20 20 20 20 20 20
Engine speed (rpm)
700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
EXCEPT FOR U5 MODEL

0.16 (0.01) 100 100 100 80 80 67 67 57 44 44 36 20 20 0.28 (0.01) 100 100 100 80 80 67 67 57 44 44 36 20 20 0.4 (0.01) 100 100 90 80 73 62 56 44 33 38 31 20 20 Intake air (g(oz)/rev) 0.52 (0.02) 0.64 (0.02) 100 90 100 90 80 73 80 68 67 62 57 51 44 40 31 24 31 31 27 20 20 20 20 20 20 20 0.76 (0.03) 80 80 67 57 57 44 36 20 20 20 20 20 20 0.92 (0.03) 64 63 54 51 51 44 34 20 20 20 20 20 20 1.1 (0.04) 48 44 40 44 44 44 31 20 20 20 20 20 20
Engine speed (rpm)
700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300
Time Needed for Diagnosis: 200 engine revs. Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judgement Value
Malfunction Criteria Catalyst damage misfire judgment value Threshold Value < Value of Map 3
GD(H4SO)-84

GENERAL DESCRIPTION

NOTE: For the detection standard, refer to DTC P0301. <Ref. to GD(H4SO)-79, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>

AW:DTC P0304 CYLINDER 4 MISFIRE DETECTED

GD(H4SO)-85

GENERAL DESCRIPTION
AX:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

Detect the open or short circuit of knock sensor. Judge as NG if out of specification.
(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(A) (1) (2)
To knock sensor harness Case Weight (3) (4) Piezoelectric element Nut (5) Resistance
3. ENABLE CONDITION

GD(H4SO)-86

GENERAL DESCRIPTION
AY:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(A) (1) (2)
3. ENABLE CONDITION

GD(H4SO)-87

GENERAL DESCRIPTION
AZ:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

Detect the open or short circuit of the crankshaft position sensor. Judge as NG when the crank signal is not input even though the starter was rotated.
(A) #1BTDC10 CA (B) #3BTDC10 CA #2BTDC10 CA #4BTDC10 CA #1BTDC10 CA
10 CA
30 CA 30 CA
EN-05538
(A)
Cam signal
(B)
Crankshaft signal
(1)
(3)
(2)
EN-05539
(1)
Crankshaft position sensor
(2)
Crank sprocket
(3)
Crankshaft half-turn
3. ENABLE CONDITION

GD(H4SO)-88

GENERAL DESCRIPTION
Malfunction Criteria Starter switch Crankshaft position sensor signal Battery voltage Threshold Value ON Not detected t8V
Malfunction Criteria Crankshaft position sensor signal Battery voltage Threshold Value Input exists t8V
GD(H4SO)-89

GENERAL DESCRIPTION
BA:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE

Detect for faults in crankshaft position sensor output properties. Judge as NG when there is a problem in the number of crankshaft signals for every revolution.
10 CA
30 CA 30 CA
EN-05538
(A)
Cam signal
(B)
Crankshaft signal
(1)
(3)
(2)
EN-05539
(1)
(2)
Crank sprocket
(3)
3. ENABLE CONDITION
Secondary Parameters Battery voltage Engine speed Enable Conditions t8V < 4000 rpm
GD(H4SO)-90

GENERAL DESCRIPTION

Perform the diagnosis continuously under 3000 rpm engine speed.
Malfunction Criteria Threshold Value Cylinder number identification Completed Amount of crank sensor signal during 1 rev. Not = 30
Time Needed for Diagnosis: 10 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Threshold Value Cylinder number identification Completed Amount of crank sensor signal during 1 rev. = 30
GD(H4SO)-91

GENERAL DESCRIPTION
BB:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

Detect the open or short circuit of the camshaft position sensor. Judge as NG when the number of camshaft signals remains abnormal.
Number of camshaft signal = 2 is normal at two engine revolution.
10 CA
30 CA 30 CA
EN-05541
(A)
Camshaft signal
(B)
Crankshaft signal
3. ENABLE CONDITION

GD(H4SO)-92

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Amount of camshaft sensor signal during 2 revs. Threshold Value t8V Not = 2
Time Needed for Diagnosis: Engine two revolutions 4 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Voltage Amount of camshaft sensor signal during 2 revs. Threshold Value t8V =2
Time Needed for Diagnosis: Two engine revolutions
GD(H4SO)-93

GENERAL DESCRIPTION
BC:DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE (BANK 1 OR SINGLE SENSOR)
Detect the malfunction of camshaft position sensor output property. Judge as NG when the camshaft line signal input timing is shifted from the crankshaft signal because of timing belt tooth chip etc.
OK (A)
NG
OK
NG
#1BTDC10 CA (B)
#3BTDC10 CA
#2BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
10 CA
30 CA 30 CA
EN-05542
(A)
Camshaft signal
(B)
Crankshaft signal
(1)
(3)
(4)
(1)
(5)
(2)
EN-01782
(1) (2)
Boss Cam sprocket
(3) (4)
Air gap Camshaft position sensor
(5)
Camshaft one revolution (engine two revolutions)
GD(H4SO)-94

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Cylinder number identification Battery voltage Engine speed Engine operation Misfire Engine load change during 4 milliseconds Enable Conditions Completed t8V 550 rpm 1000 rpm Idling Not detected d 12799.8 rpm

Always perform the diagnosis continuously at idle speed.
Malfunction Criteria Threshold Value Position of camshaft position sensor signal Not between BTDC 10CA and BTDC 80CA
Time Needed for Diagnosis: 10 engine revs. engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Threshold Value Position of camshaft position sensor signal Between BTDC 10CA and BTDC 80CA
Time Needed for Diagnosis: Two engine revolutions
GD(H4SO)-95

GENERAL DESCRIPTION
BD:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

Detect EGR system malfunction. Intake manifold pressure (negative pressure) is constant because the throttle valve is fully closed during deceleration fuel cut. At this time, when the EGR valve is opened/closed, the intake manifold pressure will change. EGR System OK/NG is judged by the range of this change.
(7)
(1) (6)
(2) (4) (3)
(5)
EN-02192
(1) (2) (3)
ECM Detecting circuit Switching circuit
(4) (5)
CPU EGR valve
(6) (7)
Main relay Battery power supply
GD(H4SO)-96

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Elapsed time after starting the engine Engine coolant temperature Engine speed Intake manifold pressure (absolute pressure) Ambient air temperature Throttle position Battery voltage Barometric pressure Vehicle speed Fuel shut-off function Neutral switch After neutral switch ON/OFF change No load change (A/C, power steering, lighting, rear defogger, heater fan and radiator fan) Enable Conditions t 40 s t 75 C(167 F) 1200 rpm 2950 rpm < 44 kPa (330 mmHg, 13 inHg) t 5 C(41 F) < 0.25 t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t58 km/h (36 MPH) In operation OFF t Value from Map t 5000 ms
Map
Engine coolant temperature C (F) After neutral switch change msec Engine coolant temperature C (F) After neutral switch change msec 40 (40) 0 30 (22) 0 20 (4) 0 10 (14) 0 0 (32) 0 10 (50) 0 20 (68) 0 30 (86) 0
40 (104) 0
50 (122) 0
60 (140) 0
70 (158) 0
80 (176) 0
90 (194) 0
100 (212) 0
110 (230) 0

During deceleration fuel cut from 53 km/h (approx. 33 MPH) or more, perform diagnosis once. Be careful of vehicle speed and engine speed. (Diagnosis will not be completed if the vehicle speed and engine speed conditions become out of specification due to deceleration.)
Measure the pressure values when the enable conditions are established, and perform diagnosis by calculating those results. 1. Label the intake manifold pressure value as PMOF1, which is observed when enable conditions are established, and set the EGR target step to 50 steps (nearly full open). 2. Label the intake manifold pressure value as PMON, which is observed after one second has passed since EGR target step was set to 50 steps (when the enable conditions were established), and set the EGR target step to 0. 3. Label the intake manifold pressure as PMOF2, which is observed after one second has passed since EGR target step was set to 0 (after two seconds have passed since the enable conditions were established). Abnormality Judgement Judge as NG when the following conditions are established. Judgement Value
Malfunction Criteria PMON (PMOF1 + PMOF2)/2 Threshold Value < 2.5 kPa (18.63 mmHg, 0.7 inHg)
Time Needed for Diagnosis: 1 time Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4SO)-97

GENERAL DESCRIPTION
Start dignosis
(A)
(B)
(C)
Deceleration fuel cut
ON OFF
Diagnosis enable condition
(Open) EGR target step (Close)
(D)
(Open) EGR actual step (Close)
PMON
Intake manifold pressure (During normal condition)
PMOF2 PMOF1
DIagnostic mode timer
EN-05568
(A) (B)
3000 ms 1000 ms
(C)
1000 ms
(D)
45 step(s)
Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria PMON (PMOF1 + PMOF2)/2 Threshold Value t 2.5 kPa (18.63 mmHg, 0.7 inHg)
Time Needed for Diagnosis: 1 time
GD(H4SO)-98

GENERAL DESCRIPTION
BE:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

Detect the deterioration of the catalyst function. Though the front oxygen sensor output would change slowly with a new catalyst, the sensor output with a deteriorated catalyst becomes high and the inversion time is shortened. For this reason, the catalyst diagnosis is carried out by monitoring the front oxygen sensor output and comparing it with the front oxygen (A/F) sensor output.
(1)
(2)
(A)
(3)
(B)
(3)
(C)
(D)
EN-01713
(A) (B) (1)
Normal Deterioration Front oxygen (A/F) sensor
(C)
Output waveform from the front oxygen (A/F) sensor Front oxygen sensor
(D)
Output waveform from the rear oxygen Sensor Catalytic converter
(2)
(3)
GD(H4SO)-99

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Battery voltage Atmospheric pressure Engine coolant temperature Estimated catalyst temperature Misfire detection every 200 rotations Learning value of evaporation gas density Sub feedback Evaporative system diagnosis Time of difference (< 0.10) between actual lambda and target lambda Vehicle speed Amount of intake air Enable Conditions t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t 70 C (158 F) t 600 C (1112 F) (AT model) t 585 C (1085 F) (MT model) < 5 time(s) < 0.2 In operation Not in operation t 1000 ms > 70 km/h (43.5 MPH) t 10 g/s (0.35 oz/s) and < 40 g/s (1.41 oz/s) < 0.02 g/rev (0 oz/rev) Experienced after fuel cut t 205 s t0s
Engine load change every 0.5 engine speed. Rear oxygen output change from 660 mV or less to 660 mV or more Elapsed time after starting the engine Purge execution calculated time

Perform the diagnosis only once at a constant 70 km/h (43.5 MPH) or higher.
After establishing the execution conditions, calculate the front oxygen (A/F) sensor lambda deviation cumulative value (6 |(sglmdn sglmdn1 )|) and rear oxygen sensor output voltage deviation cumulative value (6 |(ro2sadn ro2sadn1)|) per 32 milliseconds 4 , and when the front oxygen (A/F) sensor lambda deviation cumulative value (6 |(sglmdn sglmdn1)|) becomes the predetermined value or more, calculate the diagnostic value. Abnormality Judgement If the duration of time while the following conditions are met is within the time indicated, judge as NG. Judgement Value
Malfunction Criteria 6 |(ro2sadn ro2sadn1)| / 6 |(sglmdn sglmdn1)| Threshold Value > 10 (U5 model) > 15.5 (Except for U5 model)
Time Needed for Diagnosis: 30 55 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is within the predetermined time. Judgement Value
Malfunction Criteria 6 |(ro2sadn ro2sadn1)| / 6 |(sglmdn sglmdn1)| Threshold Value d 10 (U5 model) d 15.5 (Except for U5 model)
Time Needed for Diagnosis: 30 55 seconds
GD(H4SO)-100

GENERAL DESCRIPTION
BF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
Check if there is a leakage in fuel system or not, and perform the function diagnosis of valve.
(4) (1) (2) (3)
(5) (15)
(14) (16) (7) (9) (8) (10)
(13)
(12)
(11)
(6)
EN-04151
(1) (2) (3) (4) (5) (6)
Fuel gauge Intake manifold Throttle body Purge control solenoid valve Engine control module (ECM) Canister
(7) (8) (9) (10) (11)
Pressure control valve Drain valve Drain filter Shut-off valve Fuel temperature sensor
(12) (13) (14) (15) (16)
Fuel level sensor Fuel tank Fuel cut valve Fuel tank pressure sensor Vent valve
In this system diagnosis, check for leakage and valve function is conducted by changing the fuel tank pressure and monitoring the pressure change using the fuel tank pressure sensor. When in 0.04 inch diagnosis, perform in the order of mode Z o mode A o mode B o mode C and mode D; When in 0.02 inch diagnosis, perform in the order of mode A o mode B o mode C o mode D and mode E.
GD(H4SO)-101

GENERAL DESCRIPTION
0.04-inch Diagnosis
Mode Z
OK
Mode A
OK
Mode B
OK
Mode C
OK
Mode D NG
OK
Early OK
Large leakage judgement
END
Cancel NG OK
NG
Mode Z Extend
EN-02872
Mode Mode Z (Purge control solenoid valve opening failure diagnosis) Mode A (Estimated evaporation amount) Mode B (Sealed negative pressure, large leakage judgment) Mode C (Pressure increase check, advanced OK judgment) Mode D (Negative pressure variation measurement, evaporation leakage diagnosis)
Mode Description Perform purge control solenoid valve opening failure diagnosis from the size of tank pressure variation from diagnosis start. Calculate the tank pressure change amount (P1). Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. If the tank pressure cannot be reduced, it is diagnosed as large leak. Wait until the tank pressure returns to the target (start level of P2 calculation). If the tank pressure does not become the value, make advanced OK judgment. Calculate the tank pressure variation (P2), and obtain the diagnostic value using P1 found in Mode A. Perform the evaporation diagnosis using the diagnostic value.
Diagnosis Period 0 ms + 3000 ms 0 ms + 3000 ms + 13000 ms 10000 ms 0 10000 ms + 25000 ms 0 18500 ms
0 ms + 10000 ms
Mode Table for Evaporative Emission Control System Diagnosis

Mode Mode Z Mode A Mode B Mode C Mode D Behavior of tank internal pressure under normal conditions Roughly the same as barometric pressure (Same as 0 kPa (0 mmHg, 0 inHg)) Pressure is in proportion to amount of evaporative emission. Negative pressure is formed due to intake manifold negative pressure Reaches target pressure Pressure change is small. Diagnostic item Purge control solenoid valve is judged to be open. Large leak EVAP system large leak determination. [1.0 mm (0.04 in)] DTC P0457 None P0457 None P0442
GD(H4SO)-102

GENERAL DESCRIPTION
0.02-inch Diagnosis
Mode A
OK
Mode B
OK
Mode C
OK
Mode D
OK
Mode E
Cancel Early OK 2 Cancel Early OK 1 Cancel Cancel Cancel END
EN-02871
Mode Mode A (0 point compensation) Mode B (Negative pressure introduced) Mode C (Negative pressure maintained) Mode D (Negative pressure change calculated) Mode E (Evaporation generated amount calculation)
Mode Description When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. Wait until the tank pressure returns to the target (start level of P2 calculation). Calculate the time it takes for the tank pressure to change to the Mode E shifting pressure. If the tank pressure does not change to the Mode E shifting pressure, make advanced OK judgment. Calculate the amount of evaporation (P1).
Diagnosis Period 0 Value of Map 1 0 Value of Map 2 0 20000 ms + 0 + Value of Map 2 0 0 ms + 200000 ms 0 0 ms + 200000 ms + Value of Map 3
Map1
Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms) 0 12000 10, 2.64, 2.2 12000 20, 5.28, 4.4 11000 30, 7.93, 6.6 10000 40, 10.57, 8.8 7500 50, 13.21, 11 5000 60, 15.85, 13.2 5000
Map2
Map 3
GD(H4SO)-103

GENERAL DESCRIPTION
Pressure control solenoid valve PCV controls the fuel tank pressure to be equal to the atmospheric air pressure. Normally, the solenoid is set to OFF. The valve opens and closes mechanically in accordance with the pressure difference between tank and atmospheric air, or tank and canister. The valve is forcibly opened by setting the solenoid to ON at the time of diagnosis.
(a) (1)
(4)
(b)
(c)
(2)
(3)
EN-01715
(a) (1) (2)
Barometric pressure Solenoid Diaphragm
(b) (3)
Fuel tank Valve
(c) (4)
Canister Spring
GD(H4SO)-104

GENERAL DESCRIPTION
Valve Operation and Air Flow In the figure below, divided by the diaphragm, the part above X is charged with atmospheric air pressure, and the part below X is charged with tank pressure. Also, the part above Y is charged with tank pressure, and the part below Y is charged with canister pressure. If the atmospheric air pressure port is A, tank pressure port is B, and canister pressure port is C, the air flows according to pressure difference from each port as shown in the table below.
A (a)
B (b)
C (c)
EN-01716
(a)
Barometric pressure Condition of pressure A < B (solenoid OFF) B < C (solenoid OFF) Solenoid ON
(b)
Fuel tank Flow BoC CoB BmoC
(c)
Canister
When A < B (solenoid OFF)
A (a)
B (b)
C (c)
EN-01717
(a)
Barometric pressure
(b)
Fuel tank
(c)
Canister
GD(H4SO)-105

GENERAL DESCRIPTION
When B < C (solenoid OFF)
A (a)
B (b)
C (c)
(1) EN-01718
(a) (1)
Barometric pressure Valve
(b)
Fuel tank
(c)
Canister
When Solenoid is ON
A (a)
B (b)
C (c)
EN-01719
(a)
Barometric pressure
(b)
Fuel tank
(c)
Canister
GD(H4SO)-106

GENERAL DESCRIPTION
Drain valve Drain valve controls the ambient air to be introduced to the canister.
EN-02293
3. ENABLE CONDITION
0.04-inch Diagnosis
Secondary Parameters Battery voltage Barometric pressure Total time of canister purge operation Elapsed time after starting the engine Learning value of evaporation gas density Engine speed Fuel tank pressure Intake manifold relative vacuum (relative pressure) Vehicle speed Fuel level Enable Conditions t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t 120000 ms t 856 s < 0.08 1050 rpm 6000 rpm t 4 kPa (30 mmHg, 1.2 inHg) t 26.7 kPa ( 200 mmHg, 7.9 inHg) t 32 km/h (19.9 MPH) 9.6 2 (2.54 US gal, 2.11 Imp gal) 54.4 2 (14.37 US gal, 11.97 Imp gal) Closed air/fuel ratio control In operation Fuel temperature 10 C (14 F) 45 C (113 F) Intake air temperature t 10 C (14 F) Pressure change every one second < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) Minimum pressure change value every one sec- < 1.7 mmHg (Mode A) ond Maximum pressure change value every one second < 1.7 mmHg (Mode D) Change of fuel level per 128 milliseconds < 2 2 (0.53 US gal, 0.44 Imp gal) Air fuel ratio 0.76 1.25
GD(H4SO)-107

GENERAL DESCRIPTION
0.02-inch Diagnosis
Secondary Parameters At starting a diagnosis Evap. diagnosis Battery voltage Barometric pressure Time since last incomplete 0.02-inch leakage diagnosis When cancelling in mode A When cancelling in other than mode A Total time of canister purge operation Elapsed time after starting the engine Fuel temperature Fuel level Enable Conditions Incomplete t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg)
> 120000 ms > 600000 ms t 120000 ms t 120 s 10 C (14 F) 55 C (131 F) 9.6 2 (2.54 US gal, 2.11 Imp gal) 54.4 2 (14.37 US gal, 11.97 Imp gal) Intake manifold relative vacuum (relative pressure) t 8 kPa ( 60 mmHg, 2.4 inHg) Fuel tank pressure 0.7 kPa (5 mmHg, 0.2 inHg) 1.4 kPa (10.7 mmHg, 0.4 inHg) Vehicle speed 50 km/h (31.1 MPH) 510 km/h (316.9 MPH) continues for 125000 ms Closed air/fuel ratio control In operation Engine speed 1050 rpm 6000 rpm During diagnosis Change of fuel level d Value of Map 4 Pressure change every one second Minimum pressure change value every one second Maximum pressure change value every one second | Pressure change in tank every second | Barometric pressure change < 0.1 kPa (0.44 mmHg, 0 inHg) < 0.1 kPa (0.51 mmHg, 0 inHg) (Mode D)
d 0.1 kPa (0.75 mmHg, 0 inHg) 0.5 kPa (3.6 mmHg, 0.1 inHg) 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode D) 0.3 kPa (2.4 mmHg, 0.1 inHg) 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode E)
Map4
Fuel level (2, US gal, Imp gal) Change (2, US gal, Imp gal) 10, 2.64, 20, 5.28, 30, 7.93, 40, 10.57, 50, 13.21, 60, 15.85, 2.2 4.4 6.6 8.8 11 13.2 5, 1.32, 1.1 5, 1.32, 1.1 5, 1.32, 1.1 5, 1.32, 1.1 5, 1.32, 1.1 5, 1.32, 1.1 5, 1.32, 1.1 0

0.04-inch Diagnosis Perform the diagnosis only once in 856 seconds or more after starting the engine, at a constant speed of 32 km/h (20 MPH) or more. Pay attention to the fuel temperature and fuel level. 0.02-inch Diagnosis Perform the diagnosis 125 seconds or more at a constant engine speed of 50 km/h (31 MPH) or higher to judge as NG or OK. If judgement cannot be made, repeat the diagnosis. Pay attention to the fuel level.
GD(H4SO)-108

GENERAL DESCRIPTION
Purge control solenoid valve stuck open fault diagnosis DTC P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Purpose of Mode Z When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled. Diagnostic method Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z. Abnormality Judgement If OK judgment cannot be made, extend Mode Z, and Judge as NG when the following conditions are established after predetermined amount of time. Judgement Value
Malfunction Criteria evptez evptezha evptezini Time of 2 2 (0.53 US gal, 0.44 Imp gal) or more fuel no sloshing Threshold Value > 0.9 kPa (6.5 mmHg, 0.3 inHg) d 1.4 kPa (10.7 mmHg, 0.4 inHg) t 40000 ms DTC P0457
Time Needed for Diagnosis: 0 ms + 3000 ms + 13000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. When judgment for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis. Cancel the evaporative diagnosis when the OK/NG judgment for purge control solenoid valve stuck open cannot be made in Mode Z. Normality Judgement Judge as OK and change to Mode A when the following conditions are established after predetermined time has passed since Mode Z started. Judgement Value
Malfunction Criteria evptez evptezha Threshold Value d 0.4 kPa (3 mmHg, 0.1 inHg) DTC P0457
GD(H4SO)-109

GENERAL DESCRIPTION
Normal
(1)
(2)
evptez evptezini evptezha
(3) 0 (4)
(5) EN-02869
(1) (2)
Mode Z 3000 ms
(3) (4)
Fuel tank pressure 0.4 kPa (3 mmHg, 0.1 inHg)
(5)
OK judgment
evptez evptezha d 0.4 kPa (3 mmHg, 0.1 inHg) Normal when above is established Time Needed for Diagnosis: 0 ms + 3000 ms
GD(H4SO)-110

GENERAL DESCRIPTION
Purge control solenoid valve Open Fixation
(1) (3) (6) evptez
(2)
(4) 0
evptezini
(5)
evptezha
(7)
(8)
EN-02870
(1) (2) (3)
Mode Z Extended mode Z 3000 ms + 13000 ms
(4) (5) (6)
Fuel tank pressure 0.9 kPa (6.5 mmHg, 0.3 inHg) 1.4 kPa (10.7 mmHg, 0.4 inHg)
(7) (8)
40000 ms no fuel sloshing NG judgment
evptezini d 1.4 kPa (10.7 mmHg, 0.4 inHg) evptez evptezha > 0.9 kPa (6.5 mmHg, 0.3 inHg) No fuel sloshing of over 2 2 (0.53 US gal, 0.44 Imp gal) lasts for more than 40000 ms. Judge as abnormal when all are established.
GD(H4SO)-111

GENERAL DESCRIPTION
Leak Diagnosis DTC P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. The diagnosis is divided into the following five phases. Mode A: (Estimated evaporation gas amount) Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B. Mode B: (Negative pressure sealed) Introduce negative pressure in the intake manifold to the tank. Approx. 0 o 1.4 kPa (0 o 10.5 mmHg, 0 o 0.4 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage in the system and terminate the evaporative emission control system diagnosis. Abnormality Judgement Judge as NG (large leakage) when the following conditions are established. Judgement Value
Malfunction Criteria Time to reach target negative pressure or Mode B time (Min. pressure value in tank when in mode B) (Tank pressure when mode B started) Threshold Value DTC t 10000 ms + 25000 ms P0457 t 10000 ms > 0.3 kPa (2.5 mmHg, 0.1 inHg)
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms Mode C: (Check pressure rise) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D when the tank pressure returns to the start level of P2 calculation. Judge immediate OK and change to Mode E when it does not return in spite of spending the specified time.
Tank pressure when starting calTime for advanced OK culation of P2 judgment 1.3 kPa (9.75 mmHg, 0.4 inHg) 18500 ms
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 18500 ms Mode D: (Measure amount of negative pressure change) Monitor the tank pressure change amount when using mode D. In this case, the tank pressure increases, (nears barometric pressure) because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2. After calculating P2, perform a small leak diagnosis according to the items below. When Mode D is ended Assign tank variations measured in Mode A and Mode D, P1 and P2, to the formula below, judge small leaks in the system. If the measured judgment value exceeds the threshold value, it is judged to be a malfunction.
GD(H4SO)-112

GENERAL DESCRIPTION
Abnormality Judgement Judge as NG when the following conditions are established within the predetermined time. Judge as OK and clear the NG if the following conditions are not established within the predetermined time. Judgement Value
Malfunction Criteria P2 1.5 P1 P2: Tank pressure that changes every 10000 ms in mode D P1: Tank pressure that changes every 10000 ms in mode A Threshold Value > Value of Map 5 DTC P0442
*1.5 : Evaporation amount compensation value when below negative pressure (Amount of evaporation occurrence increases as a vacuum condition increases.)
Map 5 Malfunction criteria limit for evaporation diagnosis

Fuel temperature vs. Fuel level 25 C (77 F) 30 C (86 F) 35 C (95 F) 40 C (104 F) 45 C (113 F) 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0 2 (0 US gal, 0 Imp gal) (2.1 mmHg, (2.2 mmHg, (2.3 mmHg, (2.35 mmHg, (2.4 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 10 2 (2.64 US gal, 2.2 Imp gal) (2.1 mmHg, (2.2 mmHg, (2.3 mmHg, (2.35 mmHg, (2.4 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 20 2 (5.28 US gal, 4.4 Imp gal) (2.3 mmHg, (2.4 mmHg, (2.5 mmHg, (2.6 mmHg, (2.7 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 30 2 (7.93 US gal, 6.6 Imp gal) (2.9 mmHg, (3.05 mmHg, (3.15 mmHg, (3.25 mmHg, (3.35 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.4 kPa 0.4 kPa 0.4 kPa (3.4 mmHg, (3.5 mmHg, 40 2 (10.57 US gal, 8.8 Imp gal) (2.9 mmHg, (3.15 mmHg, (3.3 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.4 kPa 0.4 kPa 0.5 kPa (3.5 mmHg, (3.6 mmHg, (3.7 mmHg, 50 2 (13.21 US gal, 11 Imp gal) (3.2 mmHg, (3.3 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.5 kPa 60 2 (15.85 US gal, 13.2 Imp gal) (3.2 mmHg, (3.3 mmHg, (3.5 mmHg, (3.6 mmHg, (3.7 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg)
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 18500 ms + 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4SO)-113

GENERAL DESCRIPTION
Leak Diagnosis DTC P0456 Evaporative Emission Control System Leak Detected (very small leak) The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. The diagnosis is divided into the following five phases. Mode A: (0 point compensation) When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Shift to mode B when returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time. Mode B: (Negative pressure introduced) Introduce negative pressure in the intake manifold to the tank. Approx. 0 o 2 kPa (0 o 15 mmHg, 0 o 0.6 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. When the tank internal pressure does not reach the target negative pressure, the diagnosis is cancelled. Mode C: (Negative pressure maintained) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed. Mode D: (Calculate the amount of negative pressure change) Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time (evpdset) for the tank pressure to change to the Mode E shifting pressure. When the Mode E shifting pressure is reached, Mode E is entered. If it does not change to the Mode E shifting pressure after the predetermined amount of time has passed, make advanced OK judgment or cancel the diagnosis. Normality Judgement Judge as OK when the following conditions are established. Judgement Value
Malfunction Criteria Advanced OK judgment 1 Mode D time Tank internal pressure Advanced OK judgment 2 Mode D time P2 Threshold Value t 0 ms + 20000 ms d Value of Map 6 t 0 ms + 200000 ms d Value of Map 7
Map6
Fuel level (2, US gal, Imp gal) 10, 2.64, 20, 5.28, 30, 7.93, 40, 10.57, 50, 13.21, 60, 15.85, 2.2 4.4 6.6 8.8 11 13.2 1.9, 13.9, 1.9, 13.9, 1.8, 13.8, 1.8, 13.7, 1.8, 13.6, 1.8, 13.5, 1.8, 13.5, Tank pressure (kPa, mmHg, inHgl) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0, 0, 0
Map7
Fuel level (2, US gal, Imp gal) Tank pressure (kPa, mmHg, inHgl) 0, 0, 0 0.9, 7, 0.3 10, 2.64, 2.2 0.9, 7, 0.3 20, 5.28, 4.4 0.9, 7.05, 0.3 30, 7.93, 6.6 0.9, 7.1, 0.3 40, 10.57, 8.8 1.1, 8.2, 0.3 50, 13.21, 11 1.3, 9.6, 0.4 60, 15.85, 13.2 1.3, 9.6, 0.4
GD(H4SO)-114

GENERAL DESCRIPTION
Mode E: (Evaporation occurrence amount calculation) Calculate the change of tank pressure with the time evpdset to judge as NG/OK according to the value of P1. (ambiguous determination acceptable). Abnormality Judgement Judge as NG when the following conditions are established. Judgement Value
Malfunction Criteria P1 Threshold Value < Value of Map 8

Time (evpdset) vs. Fuel level 0 2 (0 US gal, 0 Imp gal) 0 ms 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 30000 ms 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 50000 ms 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.85 mmHg, 0.1 inHg) 0.3 kPa (2 mmHg, 0.1 inHg) 0.3 kPa (2 mmHg, 0.1 inHg) 100000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 160000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 200000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg)
10 2 (2.64 US gal, 2.2 Imp gal)
20 2 (5.28 US gal, 4.4 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)
40 2 (10.57 US gal, 8.8 Imp gal)
50 2 (13.21 US gal, 11 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
Time Needed for Diagnosis: Value of Map1 + Value of Map2 + 20000 ms + 0 + Value of Map2 + 0 ms + 200000 ms + Value of Map3 + 0 ms + 200000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4SO)-115

GENERAL DESCRIPTION
Normality Judgement Judge as OK when the following conditions are established. Judgement Value
Malfunction Criteria P1 Threshold Value > Value of Map 9

Time (evpdset) vs. Fuel level 0 2 (0 US gal, 0 Imp gal) 0 ms 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 30000 ms 0.5 kPa (3.5 mmHg, 0.1 inHg) 0.5 kPa (3.5 mmHg, 0.1 inHg) 0.4 kPa (3.25 mmHg, 0.1 inHg) 0.4 kPa (3 mmHg, 0.1 inHg) 0.3 kPa (2.25 mmHg, 0.1 inHg) 0.2 kPa (1.5 mmHg, 0.1 inHg) 0.2 kPa (1.5 mmHg, 0.1 inHg) 50000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 100000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 160000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 200000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg)
10 2 (2.64 US gal, 2.2 Imp gal)
20 2 (5.28 US gal, 4.4 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)
40 2 (10.57 US gal, 8.8 Imp gal)
50 2 (13.21 US gal, 11 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
Time Needed for Diagnosis: Value of Map1 + Value of Map2 + 20000 ms + 0 + Value of Map2 + 0 ms + 200000 ms + Value of Map3 + 0 ms + 200000 ms
GD(H4SO)-116

GENERAL DESCRIPTION
BG:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
Detect open or short circuit of the drain valve. Judge as NG when the ECM output level differs from the actual terminal level.
(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
Bobbin Coil Diode Stator core End plate Body Yoke
(8) (9) (10) (11) (12) (13)
Magnetic plate Shaft Plate Valve Housing Filter
(14) (15) (16) (17) (18) (19)
Retainer Diaphragm Movable core Spring Cover O-ring
3. ENABLE CONDITION

GD(H4SO)-117

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal Threshold Value t 10.9 V t 1 second Low
Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal Threshold Value t 10.9 V t 1 second High
GD(H4SO)-118

GENERAL DESCRIPTION
BH:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION

GD(H4SO)-119

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal Threshold Value t 10.9 V t 1 second High
Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal Threshold Value t 10.9 V t 1 second Low
GD(H4SO)-120

GENERAL DESCRIPTION
BI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

Detect the tank pressure sensor output property abnormality. Judge as NG when there is no pressure variation, which should exist in the tank, considering the engine status.
(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
Input voltage Terminals
(C)
To fuel tank
3. ENABLE CONDITION
Secondary Parameters Elapsed time after starting the engine Fuel level Fuel temperature Battery voltage Barometric pressure Enable Conditions t 60 s t 9.6 2 (2.54 US gal, 2.11 Imp gal) < 35 C (95 F) t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg)

Perform the diagnosis continuously after 60 s have passed since the engine started. Pay attention to the fuel level and temperature.
GD(H4SO)-121

GENERAL DESCRIPTION
Malfunction Criteria Number of times that the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more (with enable condition established) Maximum Minimum tank pressure (with enable condition completed) Maximum Minimum fuel temperature (with enable condition completed) Threshold Value t 16 time(s)
< 0 kPa (0.375 mmHg, 0 inHg) t 7 C (44.6 F)
If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is less than 2 2 (0.53 US gal, 0.44 Imp gal), extend 60 s and make judgement with the Max. and Min. values for the fuel level in 60 s 2. 60 s If a difference does not appear, extend the time (60 s 3, 60 s 4, 60 s 5) and continue the judgement. If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more, the diagnosis counter counts up. Time Needed for Diagnosis: 60 s 16 time(s) or more Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Maximum Minimum tank pressure Threshold Value t 0 kPa (0.375 mmHg, 0 inHg)
GD(H4SO)-122

GENERAL DESCRIPTION
BJ:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
Detect the open or short circuit of the fuel tank pressure sensor. Judge as NG if out of specification.
(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION

GD(H4SO)-123

GENERAL DESCRIPTION
Malfunction Criteria Fuel tank pressure Battery voltage Threshold Value < 7.4 kPa (55.6 mmHg, 2.2 inHg) t 10.9 V
Malfunction Criteria Fuel tank pressure Battery voltage Threshold Value t 7.4 kPa (55.6 mmHg, 2.2 inHg) t 10.9 V
GD(H4SO)-124

GENERAL DESCRIPTION
BK:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION
Secondary Parameters Time needed for all secondary parameters to be in enable conditions Vehicle speed All conditions of EVAP canister purge Learning value of evaporation gas concentration (left and right) Main feedback compensation coefficient (left and right) Battery voltage Enable Conditions t 5000 ms t 2 km/h (1.2 MPH) Completed < 0.08 t 0.9 t 10.9 V

Perform the diagnosis when purging enable conditions are met without idling.
GD(H4SO)-125

GENERAL DESCRIPTION
Malfunction Criteria Fuel tank pressure Fuel temperature Barometric pressure Threshold Value t 7.9 kPa (59.6 mmHg, 2.3 inHg) < 35 C (95 F) t 75 kPa (563 mmHg, 22.2 inHg)
Malfunction Criteria Fuel tank pressure Threshold Value < 7.9 kPa (59.6 mmHg, 2.3 inHg)
BL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
NOTE: For the detection standard, refer to DTC P0442. <Ref. to GD(H4SO)-101, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
BM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
NOTE: For the detection standard, refer to DTC P0442. <Ref. to GD(H4SO)-101, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-126

GENERAL DESCRIPTION
BN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve. Judge as NG when the ECM output level differs from the actual terminal level.
(B) (A)
EN-02197
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION
Secondary Parameters Battery voltage Elapsed time after starting the engine Enable Conditions t 10.9 V t 1 second

Always perform the diagnosis after starting the engine.
Malfunction Criteria Duty ratio of ON Terminal output voltage Threshold Value < 0.75 Low
Malfunction Criteria Terminal output voltage Threshold Value High
GD(H4SO)-127

GENERAL DESCRIPTION
BO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
(B) (A)
EN-02197
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION

Malfunction Criteria Duty ratio of ON Terminal output voltage Threshold Value t 0.25 High
Malfunction Criteria Terminal output voltage Threshold Value Low
GD(H4SO)-128

GENERAL DESCRIPTION
BP:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

Detect malfunctions of the fuel level sensor output property. If the fuel level does not vary in a particular driving condition / engine condition where it should, judge as NG.
(A)
(B)
EN-01734
(A)
Fuel level
(B)
Resistance
3. ENABLE CONDITION

GD(H4SO)-129

GENERAL DESCRIPTION
Malfunction Criteria Accumulated amount of intake air Max. min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine Threshold Value t 330957 g (11672.85 oz) < 2.6 2 (0.69 US gal, 0.57 Imp gal) t 10.9 V < 6000 rpm t 5000 ms
Malfunction Criteria Accumulated amount of intake air Max. min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine Threshold Value t 330957 g (11672.85 oz) t 2.6 2 (0.69 US gal, 0.57 Imp gal) t 10.9 V < 6000 rpm t 5000 ms
GD(H4SO)-130

GENERAL DESCRIPTION
BQ:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.
(1)
(5)
(4)
(2)
(3)
EN-05371
(1) (2)
Engine control module (ECM) Fuel level sensor
(3) (4)
Fuel sub level sensor Detecting circuit
(5)
Body integrated unit
3. ENABLE CONDITION

GD(H4SO)-131

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage Threshold Value t 10.9 V t 3000 ms < 0.173 V
Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage Threshold Value t 10.9 V t 3000 ms t 0.173 V
GD(H4SO)-132

GENERAL DESCRIPTION
BR:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

(1)
(5)
(4)
(2)
(3)
EN-05371
(1) (2)
(3) (4)
Fuel sub level sensor Detecting circuit
(5)
Body integrated unit
3. ENABLE CONDITION

GD(H4SO)-133

GENERAL DESCRIPTION
GD(H4SO)-134

GENERAL DESCRIPTION
BS:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

Detect the unstable output faults from the fuel level sensor caused by noise. Judge as NG when the max. value and cumulative value of output voltage variation of the fuel level sensor is larger than the threshold value.
2. ENABLE CONDITION
Malfunction Criteria Engine speed Elapsed time after starting the engine Battery voltage Idle switch Fuel level Threshold Value t 500 rpm t 1 second t 10.9 V ON t 9.6 2 (2.54 US gal, 2.11 Imp gal) and < 54.4 2 (14.37 US gal, 11.97 Imp gal) t 10000 ms
Vehicle speed = 0 km/h (0 MPH)

Always perform the diagnosis continuously at idle speed. Pay attention to the fuel level.
GD(H4SO)-135

GENERAL DESCRIPTION
Calculate the Max. value (DELFLMAX) and cumulative value (SUMFL) of output voltage variation of fuel level sensor during 12.2 seconds. Judge it normal when both max. and cumulative values are not over the threshold value. Otherwise, when either of them is over the threshold value, the diagnosis counter counts up. Judge as NG if the counter indicated 4 time(s).
Diagnosis condition
(A)
Diagnosis timer
Fuel level sensor A/D value
(C) (D)
Amount of Fuel level output voltage variation
Calculate the Max. value (DELFLMAX) and the cumulative value (SUMFL). 6 5 4 3 2 1 Diagnosis counter 0
(B) EN-05569
(A) (B)
12288 ms NG at 4 time(s)
(C)
Malfunction
(D)
Normal
GD(H4SO)-136

GENERAL DESCRIPTION
Malfunction Criteria Threshold Value Integrated times of the condition reaching t 4 time(s) follows, DELFLMAX t Value from Map or SUMFL t 25.92 V At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms
Map
Fuel level (2, US gal, Imp gal) Measured voltage (V) 0, 0, 0 0.27 10, 2.64, 2.2 0.27 20, 5.28, 4.4 0.426 30, 7.93, 6.6 0.582 40, 10.57, 8.8 0.738 50, 13.21, 11 0.894 60, 15.85, 13.2 0.894
The diagnosis counter does not count up when the following conditions are completed within 12288 ms.
Maximum value Minimum value of change of tank pressure for 12288 ms Maximum value Minimum value of battery voltage for 12288 ms t 0 kPa (0.375 mmHg, 0 inHg) t 0.609 V
Time Needed for Diagnosis: 12288 ms 4 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Threshold Value DELFLMAX < Value from Map SUMFL < 25.92 V At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms
GD(H4SO)-137

GENERAL DESCRIPTION
BT:DTC P0500 VEHICLE SPEED SENSOR A

Judge as NG when outside of the judgment value. Judge NG when the received data from ABSCM&H/U is abnormal vehicle speed, and the vehicle speed data is impossible.
Vehicle speed signals are taken in to the ABS control module and hydraulic control unit, and normal/erroneous data of the ABS wheel speed sensor is received by CAN communication from the ABS control module and hydraulic control unit.
3. ENABLE CONDITION
Secondary Parameters Battery voltage Elapsed time after engine starting Enable Conditions t 10.9 V t 2000 ms

Always perform diagnosis more than 2000 ms after starting the engine.
Malfunction Criteria Front ABS wheel speed sensor status Either of the following is established Front left wheel speed Front right wheel speed Threshold Value Malfunction t 300 km/h (186.4 MPH) t 300 km/h (186.4 MPH)
Malfunction Criteria Front left wheel speed Threshold Value > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH) > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH)
Front right wheel speed
GD(H4SO)-138

GENERAL DESCRIPTION
BU:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as NG when actual engine speed is not close to target engine speed during idling.
2. ENABLE CONDITION
Secondary Parameters Engine coolant temperature Battery voltage Atmospheric pressure Fuel level Elapsed time after starting the engine Feedback of ISC Lambda value (left and right) Enable Conditions t 75 C (167 F) t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t 9.6 2 (2.54 US gal, 2.11 Imp gal) t 10.49 s In operation t 0.81 and < 1.1 t 5.1 s > 5.1 s > 5.1 s 0 km/h (0 MPH)
After switching air conditioner to ON/ OFF After intake manifold pressure changes by 4 kPa (30 mmHg, 1.2 inHg) or more. Elapsed time after switching neutral position switch to ON/OFF Vehicle speed

Perform the diagnosis continuously at idling after warming up engine.
Malfunction Criteria Actual engine speed Targeted engine speed Feedback compensation for ISC Threshold Value < 100 rpm Max.
Time Needed for Diagnosis: 10 s 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Actual engine speed Targeted engine speed Threshold Value t 100 rpm
GD(H4SO)-139

GENERAL DESCRIPTION
BV:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION

Malfunction Criteria Actual Target engine speed Feedback value for ISC Threshold Value t 200 rpm Min.
Malfunction Criteria Actual Target engine speed Threshold Value < 200 rpm
GD(H4SO)-140

GENERAL DESCRIPTION
BW:DTC P0512 STARTER REQUEST CIRCUIT

Detect the open or short circuit of starter SW. Judge as ON NG when the starter SW signal remains ON.
2. ENABLE CONDITION

Malfunction Criteria Engine condition Starter OFF signal Battery voltage Threshold Value After engine starting Not detected t8V
Malfunction Criteria Starter OFF signal Battery voltage Threshold Value Detected t8V
GD(H4SO)-141

GENERAL DESCRIPTION
BX:DTC P0513 INCORRECT IMMOBILIZER KEY

DTC P0513 P1570 P1571 P1572 P1574 P1576 P1577 P1578 Item Incorrect Immobilizer Key Antenna Reference Code Incompatibility IMM Circuit Failure (Except Antenna Circuit) Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Outline of Diagnosis Incorrect immobilizer key (Use of unregistered key in body integrated unit) Faulty antenna Reference code incompatibility between body integrated unit and ECM Communication failure between body integrated unit and ECM Failure of body integrated unit to verify key (transponder) ID code or transponder failure ECM malfunctioning Body integrated unit malfunctioning Reference code incompatibility between body integrated unit and combination meter
2. ENABLE CONDITION
When starting the engine.

Perform the diagnosis only after starting the engine.
Judge as NG when the conditions for the outline of the diagnosis of the top are established.
GD(H4SO)-142

GENERAL DESCRIPTION
BY:DTC P0600 SERIAL COMMUNICATION LINK

Detect malfunction of CAN communication. When CAN communications is not possible, and CAN communications with TCM is not possible, judge as NG if data from the TCM is not normal.
ECM and TCM are connected by high speed CAN. (Common Specifications) CAN Protocol 2.0 B (Active) Frame Format: 11 Bit ID Frame (Standard Frame) (High speed CAN) Conforms to ISO11898 Communication Speed: 500 kbps
3. ENABLE CONDITION

Malfunction Criteria Battery voltage Starter switch Engine bus off flag or error warning flag or ID received from control module connected to driving system CAN or Data updated from control module connected to driving system CAN Threshold Value > 10.9 V OFF run set (error) None during 500 milliseconds None during 500 milliseconds
Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-143

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Starter switch Engine bus off flag or error warning flag ID received from control module connected to driving system CAN Data updated from control module connected to driving system CAN Threshold Value > 10.9 V OFF run clear (No error) Yes Yes
Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-144

GENERAL DESCRIPTION
BZ:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
Detect the malfunction of microcomputer (RAM). When there is a problem in the main CPU normal RAM, or the sub CPU normal RAM, judge as NG. Judge as OK when both are operating properly. If it is possible to write data to the whole area of RAM in the initial routine, and is possible to read the same data, it is judged as OK, and if not, NG.
2. ENABLE CONDITION
Diagnosis with the initial routine.

Perform the diagnosis as soon as the ignition switch is turned to ON.
Malfunction Criteria Main CPU normal RAM abnormal Write 5AA5A55A and then read. (Whole area of RAM) Write A55A5AA5 and then read. (Whole area of RAM) Sub CPU normal RAM abnormal Write 5AA5 and then read. (Whole area of RAM) Write A55A and then read. (Whole area of RAM) Threshold Value 5AA5A55A cannot be read. A55A5AA5 cannot be read. 5AA5 cannot be read. A55A cannot be read.
Time Needed for Diagnosis: Undetermined Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG when the malfunction criteria below are met. Judgement Value
Malfunction Criteria Main CPU normal RAM abnormal Write 5AA5A55A and then read. (Whole area of RAM) And write A55A5AA5 and then read. (Whole area of RAM) Sub CPU normal RAM abnormal Write 5AA5 and then read. (Whole area of RAM) And write A55A and then read. (Whole area of RAM) Threshold Value 5AA5A55A can be read. A55A5AA5 can be read. 5AA5 can be read. A55A can be read.
GD(H4SO)-145

GENERAL DESCRIPTION
CA:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
Judge as NG when SUM value of ROM is outside the standard value.
2. ENABLE CONDITION
Secondary Parameters Ignition switch Enable Conditions ON

Malfunction Criteria SUM value of ROM Threshold Value Standard
Time Needed for Diagnosis: Undetermined Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-146

GENERAL DESCRIPTION
CB:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE

Judge as NG when any one of the followings is established. 1) When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU. 2) When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and sub CPU. 3) When the sub CPU operates abnormally. 4) When the communication between main CPU mo sub CPU is abnormal. 5) When the input amplifier circuit of throttle position sensor 1 is abnormal. 6) When the cruise control cannot be canceled correctly. 7) When the signal of brake SW1 and 2 is mismatched.
(12) (1)
(2) (11) (10)
(13) (10) (3)
(4) (5)
(10) (14)
(6) (10)
(7) (8) (9) EN-01862
(1) (2) (3) (4) (5)
Throttle position sensor Throttle position sensor 1 Throttle position sensor 2 Accelerator pedal position sensor Accelerator pedal position sensor 1
(6) (7) (8) (9) (10)
Accelerator pedal position sensor 2 Battery Stop light Brake switch I/F circuit
(11) (12) (13) (14)
Amplifier circuit Engine control module (ECM) Sub CPU Main CPU
GD(H4SO)-147

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Enable Conditions (1) Ignition switch ON (2) Ignition switch ON (3) None (4) None (5) Throttle opening angle (6) Brake switch (only with cruise control) ON (7) None

(1) (4): Always perform the diagnosis continuously. (5): Always perform the diagnosis continuously when idling. (6): Perform the diagnosis when the brake pedal is depressed. (7): Always perform the diagnosis continuously. (8): Always perform the diagnosis continuously when the cruise control pedal is not operating.
Judge as OK and clear the NG when the malfunction criteria below are met. Judgement Value
Malfunction Criteria (1) Difference of CPU reading value of the throttle position sensor signal (2) Difference of CPU read value of the accelerator pedal position sensor signal (3) WD pulse from sub CPU (4) Communication between CPU (5) |Throttle position sensor 1 opening angle (Throttle position sensor 1 opening angle after passing amplifier) 1/4| (6) Cruise control cancel signal at brake ON (7) Brake switch 1, 2 signal Threshold Value d 0.0858 V d 0.35 V WD pulse occur Possible to communicate < 3
Cruise control cancel signal ON SW 1 and 2 are matched
Time Needed for Diagnosis: 1. 600 ms 2. 830 ms 3. 200 ms 4. 200 ms 5. 24 ms 6. 250 ms 7. 200 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-148

GENERAL DESCRIPTION
CC:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)

Judge as NG when the target opening angle and actual opening angle is mismatched or the current to motor is the specified duty or more for specified time continuously.
(3)
(1)
(4)
(2)
EN-01863
(1) (2)
Motor Throttle position sensor
(3)
(4)
Drive circuit
3. ENABLE CONDITION
Secondary Parameters Ignition switch Normal operation of electronic throttle control Enable Conditions ON ON

Always perform the diagnosis continuously when the electronic throttle control is operating.
Malfunction Criteria Difference between target opening angle and actual opening angle Output duty to drive circuit Threshold Value 3.5 or less 95% or less
Time Needed for Diagnosis: Target opening angle and actual opening angle: 250 milliseconds (For NG) 2000 milliseconds (For OK) Output duty to drive circuit: 2000 milliseconds
GD(H4SO)-149

GENERAL DESCRIPTION
Details of Judgement Value
30 (25.0) 20 (3) (1) (12.0) 10 (5.0) (3.5) 0 0 5 (6.15) 10 (9.65) 15 (14.65) (2) EN-03129 20 25 (26.65) 30
(1)
Difference between target opening angle and actual opening angle ()
(2)
Target throttle opening angle ()
(3)
NG area
Details of Judgement time (The actual opening angle d target opening angle is always 1000 milliseconds)
1000
(1)
500 (400) (300) (250)
(3)
0 0 5 (5.5) (9.0) 10 (13.0) 15 (2) 20 (22.0) 25 30
EN-01865
(1)
Judgement time (milliseconds)
(2)
Throttle position sensor 1 opening angle
(3)
NG area
Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-150

GENERAL DESCRIPTION
CD:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

Judge as NG when there is CAN communication with the TCM and there is a MIL lighting request.
2. ENABLE CONDITION

Malfunction Criteria Battery voltage MIL lighting request from TCM Threshold Value t 10.9 V Yes
Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Battery voltage MIL lighting request from TCM Threshold Value t 10.9 V None
GD(H4SO)-151

GENERAL DESCRIPTION
CE:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)

Judge the open or short circuit of the neutral SW. Judge as NG when the ECM neutral terminal input differs from the reception data from TCM.
2. ENABLE CONDITION
Secondary Parameters Battery voltage Starter relay Enable Conditions t 10.9 V OFF

Perform the diagnosis continuously in 2 seconds after starting the engine.
Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are OFF and when the other switches are ON Threshold Value LOW (ON)
Time Needed for Diagnosis: 100 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are OFF and when the other switches are ON Threshold Value HIGH (OFF)
GD(H4SO)-152

GENERAL DESCRIPTION
CF:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

Detect the open or short circuit of neutral SW. Judge as NG when there is no change in the neutral SW even if the driving shift was applied. (There is neutral SW ON/OFF inversion from the vehicle speed and engine speed.)
2. ENABLE CONDITION

Abnormality Judgement Judge NG when the malfunction criteria below are completed determined times or more after the neutral SW change. Judgement Value
Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value LOW (ON) continues. From a) to b)
Time Needed for Diagnosis: 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear NG when there is change in the neutral SW. Judgement Value
Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value Changes to HIGH (OFF). From a) to b)
GD(H4SO)-153

GENERAL DESCRIPTION
CG:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)

2. ENABLE CONDITION

Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are ON and when the other switches are OFF Threshold Value HIGH (OFF)
Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are ON and when the other switches are OFF Threshold Value LOW (ON)
GD(H4SO)-154

GENERAL DESCRIPTION
CH:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

2. ENABLE CONDITION

Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value HIGH (OFF) continues. From a) to b)
Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value Changes to LOW (ON). From a) to b)
GD(H4SO)-155

GENERAL DESCRIPTION
CI: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)

Detect that O value remains low. Judge as NG when lambda value is abnormal in accordance with O value of front oxygen (A/F) sensor and running conditions such as vehicle speed, amount of intake air, engine coolant temperature, sub feedback control, etc.
O value = Actual air fuel ratio/Theoretical air fuel ratio O > 1: Lean O < 1: Rich
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
GD(H4SO)-156

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 180CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient Enable Conditions t 4096 ms t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) Execution 0.2 V 0.1 V On Min. On Max. t 60000 ms t 75 C (167 F) t 20 km/h (12.4 MPH) t 6 g/s (0.21 oz/s) < 0.02 g/rev (0 oz/rev) 0 : 50 : < 0.2 t 19.9 s 0.03 0.000

Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have passed since the engine started.
Malfunction Criteria O value Threshold Value < 0.85
Malfunction Criteria O value Threshold Value t 0.85
GD(H4SO)-157

GENERAL DESCRIPTION
CJ:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)

Detect that O value remains high. Judge as NG when lambda value is abnormal in accordance with O value of front oxygen (A/F) sensor and running conditions such as vehicle speed, amount of intake air, engine coolant temperature, sub feedback control, etc.
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
GD(H4SO)-158

GENERAL DESCRIPTION
3. ENABLE CONDITION

Malfunction Criteria O value Threshold Value > 1.15
Malfunction Criteria O value Threshold Value d 1.15
GD(H4SO)-159

GENERAL DESCRIPTION
CK:DTC P1160 RETURN SPRING FAILURE

Judge as NG when the valve is opened more than the default opening angle, but does not move to the close direction with the motor power stopped.
(1)
(8)
S S
(3) (6) (2) (4) (5) (7)
EN-01866
(1) (2) (3)
Opener spring Return spring Intermediate stopper
(4) (5) (6)
Full closed stopper Throttle valve Gear
(7) (8)
DC motor Main and sub throttle sensor
3. ENABLE CONDITION
Secondary Parameters Motor continuity Enable Conditions OFF

Ignition switch ON o OFF Ignition switch OFF o ON (Only after clearing memory)
Malfunction Criteria Opening variation after continuity is set to OFF Threshold Value t 2
Time Needed for Diagnosis: 1880 milliseconds Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-160

GENERAL DESCRIPTION
CL:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
Detect the open/short circuit of pressure control solenoid valve. Judge as NG when ECM output level is different from actual terminal level.
(1)
(A) (2) (3) (4)
(B)
(C)
(5) EN-01759
(A) (1) (2)
Barometric pressure Filter Coil
(B) (3) (4)
Shut-off valve Connector terminal Diaphragm
(C) (5)
To fuel tank Valve
3. ENABLE CONDITION

GD(H4SO)-161

GENERAL DESCRIPTION
GD(H4SO)-162

GENERAL DESCRIPTION
CM:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
(1)
(A) (2) (3) (4)
(B)
(C)
(5) EN-01759
(A) (1) (2)
(B) (3) (4)
(C) (5)
To fuel tank Valve
3. ENABLE CONDITION

GD(H4SO)-163

GENERAL DESCRIPTION
GD(H4SO)-164

GENERAL DESCRIPTION
CN:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

Detect the abnormal function (stuck closed) of the drain valve. Judge as NG when fuel tank pressure is low.
(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION
Secondary Parameters Drain valve Battery voltage Barometric pressure Tank pressure when starter is OFF o ON Enable Conditions Open t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) 0.4 kPa (3.2 mmHg, 0.1 inHg) and 1.4 kPa (10.7 mmHg, 0.4 inHg)

GD(H4SO)-165

GENERAL DESCRIPTION
Malfunction Criteria Fuel tank pressure Threshold Value d 4 kPa (30 mmHg, 1.2 inHg)
Time Needed for Diagnosis: 3000 s Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Fuel tank pressure Cumulative time when all the malfunction criteria below are met. Purge control solenoid valve duty Fuel temperature Intake manifold relative pressure Threshold Value > 4 kPa (30 mmHg, 1.2 inHg) t 30000 s Not = 0 10 C (14 F) 70 C (158 F) t 26.7 kPa (200 mmHg, 7.9 inHg)
GD(H4SO)-166

GENERAL DESCRIPTION
CO:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM

Detect the blow-by hose release abnormality. Judge as NG when the diagnosis terminal voltage is high.
(1)
(4)
(2)
(3)
EN-01790
(1) (2)
Engine control module (ECM) Detecting circuit
(3)
PCV diagnosis connector
(4)
5V
3. ENABLE CONDITION

GD(H4SO)-167

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Engine condition Positive crankcase ventilation diagnosis voltage Threshold Value t 10.9 V After engine starting High
Malfunction Criteria Battery voltage Engine condition Positive crankcase ventilation diagnosis voltage Threshold Value t 10.9 V After engine starting Low
GD(H4SO)-168

GENERAL DESCRIPTION
CP:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
Detects open or short circuit of EGR. Judge as NG when the ECM output level differs from the actual terminal level.
(5)
(1) (6)
(3) (2) (4)
EN-02051
(1) (2)
Engine control module (ECM) Computer unit (CPU)
(3) (4)
Detecting circuit Switch circuit
(5) (6)
Battery voltage Main relay
3. ENABLE CONDITION
Secondary Parameters Elapsed time after starting the engine EGR valve target position Battery voltage Enable Conditions t 1 second > 0 step t 10.9 V

Perform diagnosis continuously during EGR operation.
GD(H4SO)-169

GENERAL DESCRIPTION
Malfunction Criteria Terminal voltage level when ECM outputs OFF signal or Terminal voltage level when EGR operates Threshold Value Low level
Low level
Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Terminal voltage level when ECM outputs OFF signal Terminal voltage level when EGR operates Threshold Value High level High level
GD(H4SO)-170

GENERAL DESCRIPTION
CQ:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
(5)
(1) (6)
(3) (2) (4)
EN-02051
(1) (2)
(3) (4)
(5) (6)
3. ENABLE CONDITION

GD(H4SO)-171

GENERAL DESCRIPTION
Malfunction Criteria Terminal voltage level when ECM outputs OFF signal or Terminal voltage level when EGR operates Threshold Value High level
High level
Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Terminal voltage level when ECM outputs OFF signal Terminal voltage level when EGR operates Threshold Value Low level Low level
GD(H4SO)-172

GENERAL DESCRIPTION
CR:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
NOTE: For the detection standard, refer to DTC P1492. <Ref. to GD(H4SO)-169, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CS:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
NOTE: For the detection standard, refer to DTC P1493. <Ref. to GD(H4SO)-171, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CT:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
CU:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
CV:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
CW:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
GD(H4SO)-173

GENERAL DESCRIPTION
CX:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

Detect the open/short circuit of back-up power supply circuit. Judge as NG when the backup power voltage is low.
2. ENABLE CONDITION

Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition Threshold Value Low t 10.9 V After engine starting
Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition Threshold Value High t 10.9 V After engine starting
GD(H4SO)-174

GENERAL DESCRIPTION
CY:DTC P1570 ANTENNA

NOTE: For the detection standard, refer to DTC P0513. <Ref. to GD(H4SO)-142, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CZ:DTC P1571 REFERENCE CODE INCOMPATIBILITY

DA:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

DB:DTC P1574 KEY COMMUNICATION FAILURE

DC:DTC P1576 EGI CONTROL MODULE EEPROM

DD:DTC P1577 IMM CONTROL MODULE EEPROM

DE:DTC P1578 METER FAILURE

GD(H4SO)-175

GENERAL DESCRIPTION
DF:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

Detect malfunctions of the catalyst advanced idling retard angle control. Judge as NG when ECM is not controlling the angle properly during catalyst advanced idling retard angle control. Judge as NG if there is exhaust gas temperature diagnosis and idle speed diagnosis and if either of them is NG. Exhaust gas temperature diagnosis Judge as NG when the estimated exhausted gas temperature in 14 seconds after the cold start is below the specified value. Idle speed diagnosis Judge as NG when actual engine speed is not close to target engine speed after terminating the retard angle control.
2. ENABLE CONDITION
Secondary Parameters Atmospheric pressure Battery voltage Cold start diagnosis Vehicle speed Misfire in 200 engine revs. Time after starting Enable Conditions t 75 kPa (563 mmHg, 22.2 inHg) t 10.9 V Incomplete < 2 km/h (1.2 MPH) <5 = 14 seconds

Perform the diagnosis at cold start.
Exhaust temperature diagnosis Abnormality Judgement When the diagnostic execution conditions are established, calculate the estimated exhaust temperature. Judge as NG when the following conditions are established after engine starting within the predetermined time. Judgement Value
Malfunction Criteria Estimated exhaust gas temperature Threshold Value < Value from Map
Map U5 model
Coolant temperature after starting the engine Threshold value (AT model) Threshold value (MT model) 40 C (40 F) 30 C (22 F) 20 C (4 F) 10 C (14 F) 0 C (32 F) 10 C (50 F) 20 C (68 F) 30 C (86 F) 40 C (104 F) 50 C (122 F)
220 C 220 C 220 C 220 C 220 C 214 C 206 C 206 C 184 C 178 C (428 F) (428 F) (428 F) (428 F) (428 F) (417.2 F) (402.8 F) (402.8 F) (363.2 F) (352.4 F) 214 C 214 C 214 C 214 C 214 C 214 C 214 C 198 C 194 C 190 C (417.2 F) (417.2 F) (417.2 F) (417.2 F) (417.2 F) (417.2 F) (417.2 F) (388.4 F) (381.2 F) (374 F)
GD(H4SO)-176

GENERAL DESCRIPTION
Except for U5
Coolant tempera40 C 30 C 20 C 10 C 0 C 10 C 20 C 30 C 40 C 50 C ture after starting (40 F) (22 F) (4 F) (14 F) (32 F) (50 F) (68 F) (86 F) (104 F) (122 F) the engine Threshold value 162 C 162 C 162 C 162 C 162 C 162 C 162 C 154 C 142 C 142 C (AT model) (323.6 F) (323.6 F) (323.6 F) (323.6 F) (323.6 F) (323.6 F) (323.6 F) (309.2 F) (287.6 F) (287.6 F) Threshold value 168 C 168 C 168 C 168 C 168 C 168 C 168 C 160 C 145 C 145 C (MT model) (334.4 F) (334.4 F) (334.4 F) (334.4 F) (334.4 F) (334.4 F) (334.4 F) (320 F) (293 F) (293 F)
Time Needed for Diagnosis: 14 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria Estimated exhaust gas temperature Threshold Value t Value from Map
Time Needed for Diagnosis: Less than 1 second Idle speed diagnosis Abnormality Judgement Judge as NG when the following conditions are established after the predetermined time. Judgement Value
Malfunction Criteria Continuous time of (Target engine speed Actual engine speed > 200 rpm) (U5 model) Continuous time of (Target engine speed Actual engine speed > 300 rpm) (Other than U5 model) Continuous time of (actual retard amount > 30 CA) Threshold Value t 6000 ms
t 0 ms
Malfunction Criteria Continuous time of (Target engine speed Actual engine speed > 200 rpm) (U5 model) Continuous time of (Target engine speed Actual engine speed > 300 rpm) (Other than U5 model) Continuous time of (actual retard amount > 30 CA) Threshold Value < 6000 ms
< 0 ms
GD(H4SO)-177

GENERAL DESCRIPTION
DG:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
Detect the malfunction of fuel system from the size of the sub feedback learning value. Control the sub feedback learning and judge as NG when the learning value is in the lean zone.
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION
Secondary Parameters Conditions for carrying out the sub feedback learning Continuous time when all conditions are established. Enable Conditions Completed t1s

Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50 MPH) or more.
GD(H4SO)-178

GENERAL DESCRIPTION
Malfunction Criteria Sub feedback learning value Threshold Value < 0.04
Malfunction Criteria Sub feedback learning value Threshold Value t 0.04 + 0
GD(H4SO)-179

GENERAL DESCRIPTION
DH:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
Detect the malfunction of fuel system from the size of the sub feedback learning value. Sub feedback learning is being performed. When the learning value goes to the rich side, judge as NG.
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION

GD(H4SO)-180

GENERAL DESCRIPTION
Malfunction Criteria Sub feedback learning value Threshold Value t 0.03 (U5 model) t 0.04 (Other than U5 model)
Malfunction Criteria Sub feedback learning value Threshold Value < 0.03 + 0.002 (U5 model) < 0.04 + 0.002 (Other than U5 model)
GD(H4SO)-181

GENERAL DESCRIPTION
DI: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE
Judge as NG when the motor current becomes large or drive circuit is heated.
12V (1) 12V
(6)
(2)
(3)
(4)
(7)
(2)
(5) EN-01867
(1) (2) (3)
Engine control module (ECM) Detecting circuit Overcurrent detection circuit
(4) (5)
Drive circuit Temperature detection circuit
(6) (7)
Electronic throttle control relay Motor
3. ENABLE CONDITION
Secondary Parameters Enable Conditions Under control of electronic throttle control ON

Malfunction Criteria Motor current Drive circuit inner temperature Threshold Value d8A d 175C (347F)
Time Needed for Diagnosis: 500 milliseconds (For NG) 2000 milliseconds (For OK) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-182

GENERAL DESCRIPTION
DJ:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

Judge as NG when the electronic throttle control power is not supplied even when ECM sets the electronic throttle control relay to ON.
12V (1) 12V
(4)
(2)
(3)
(5)
EN-01868
(1) (2)
Engine control module (ECM) Voltage detection circuit
(3) (4)
Drive circuit Electronic throttle control relay
(5)
Motor
3. ENABLE CONDITION
Secondary Parameters Electronic throttle control relay output Enable Conditions ON

Malfunction Criteria Motor power voltage Threshold Value t5V
GD(H4SO)-183

GENERAL DESCRIPTION
DK:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

Judge as NG when the electronic throttle control power is supplied even when ECM sets the electronic throttle control relay to OFF.
12V (1) 12V
(4)
(2)
(3)
(5)
EN-01868
(1) (2)
(3) (4)
(5) Motor
3. ENABLE CONDITION
Secondary Parameters Electronic throttle control relay output Enable Conditions OFF

When ignition switch ON o OFF Ignition switch OFF o ON (Only after clearing memory)
Malfunction Criteria Motor power voltage Threshold Value d5V
GD(H4SO)-184

GENERAL DESCRIPTION
DL:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE

Judge as NG when full close point learning cannot conducted or abnormal value is detected.
(1)
(3)
(2)
(4)
EN-01869
(1) (2)
Engine control module (ECM) Drive circuit
(3)
Motor
(4)
3. ENABLE CONDITION
Secondary Parameters Ignition switch Ignition switch (only after clear memory) Enable Conditions ON o OFF OFF o ON

Perform the diagnosis at full closed point learning.
Malfunction Criteria Throttle sensor opening angle at full close point learning Throttle opening angle when the ignition switch is ON Throttle minimum stop position Threshold Value 10.127 or more, 19.872 or less t 1.683
Time Needed for Diagnosis: 8 80 milliseconds Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4SO)-185

GENERAL DESCRIPTION
DM:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT

Detect the open or short circuit of accelerator pedal position sensor 1. Judge as NG if out of specification.
(4) (1)
(2)
(3)
EN-01861
(1) (2)
Engine control module (ECM) Accelerator pedal position sensor 1 signal
(3)
Accelerator pedal position sensor 2 signal
(4)
3. ENABLE CONDITION

GD(H4SO)-186

GENERAL DESCRIPTION
GD(H4SO)-187

GENERAL DESCRIPTION
DN:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4SO)-188

GENERAL DESCRIPTION
GD(H4SO)-189

GENERAL DESCRIPTION
DO:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4SO)-190

GENERAL DESCRIPTION
GD(H4SO)-191

GENERAL DESCRIPTION
DP:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4SO)-192

GENERAL DESCRIPTION
GD(H4SO)-193

GENERAL DESCRIPTION
DQ:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.
(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4SO)-194

GENERAL DESCRIPTION
Malfunction Criteria Signal difference between two sensors Threshold Value > Value from Map
Map
Throttle position sensor 1 opening angle () = d Sensor output difference () 0 d d < 2.125 5.15 2.125 d d < 4.25 6.15 4.25 d d < 9 8.28 9 d d < 31.625 10.4 31.625 d d 12.4
Malfunction Criteria Signal difference between two sensors Threshold Value d Value from Map
GD(H4SO)-195

GENERAL DESCRIPTION
DR:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4SO)-196

GENERAL DESCRIPTION
Map
Throttle position sensor 1 opening angle () = d Sensor output difference () 0d d < 0.6 1.465 0.6 d d < 1.2 1.597 1.2 d d < 2 1.663 2dd<4 2.455 4dd 3.116
GD(H4SO)-197

GENERAL DESCRIPTION
DS:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE

Detect the malfunction of barometric pressure sensor output property. Judge as NG when the barometric pressure sensor output is largely different from the intake manifold pressure at engine start.
The barometric pressure sensor is built into the ECM.
3. ENABLE CONDITION
Secondary Parameters Engine speed Vehicle speed Enable Conditions < 300 rpm < 1 km/h (0.6 MPH)

Perform the diagnosis once at ignition switch ON.
Malfunction Criteria |Barometric pressure Intake manifold pressure| |Intake manifold pressure at engine start Intake manifold pressure| Threshold Value t 26.7 kPa (200 mmHg, 7.9 inHg) < 1.3 kPa (9.99 mmHg, 0.4 inHg)
Malfunction Criteria |Barometric pressure Intake manifold pressure| Threshold Value < 26.7 kPa (200 mmHg, 7.9 inHg)
GD(H4SO)-198

GENERAL DESCRIPTION
DT:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW

Detect the open/short circuit of the barometric pressure sensor. Judge as NG if out of specification.
3. ENABLE CONDITION

GD(H4SO)-199

GENERAL DESCRIPTION
DU:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH

3. ENABLE CONDITION

GD(H4SO)-200
General Description
A: SPECIFICATION
Fuel tank Capacity Location Type Shutoff discharge pressure Discharge rate Fuel filter 64 2 (16.9 US gal, 14.1 Imp gal) Under rear seat Impeller 550 850 kPa (5.61 8.67 kg/cm2, 79.8 123.3 psi) 155 2 (40.9 US gal, 34.1 Imp gal)/h or more. [12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)] In-tank type
Fuel pump
FU(H4DOTC)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T3
(18) T3
T2
(15)
(23) T2 T2 (24) (19) (16) (17) (4) T2 (23) T2 (27) (20) (26) T4 (14) (10) T4 T2 T1 (3) (2) T4 (11) (11) T1 A (3) T5 B T5 (9) (9) (11) T4 (7) (8) (7) (8) (21) T4 T4 FU-03454 (10) (11) (10) T2 (13) (1) T4 T2 (12) (25) (5) (6) B
T4
(22)
(8)
FU(H4DOTC)-3
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Pressure regulator Fuel hose Clamp Purge control solenoid valve 1 Vacuum hose D Vacuum hose C Intake manifold gasket Guide pin Tumble generator valve ASSY Fuel injector Seal ring Purge control solenoid valve 2 (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) Fuel injector pipe LH (24) Solenoid valve bracket Fuel injector pipe RH (25) Vacuum hose B Solenoid valve bracket (26) Vacuum hose A Manifold absolute pressure sensor (27) Air control hose Filter Intake manifold Tightening torque:Nm (kgf-m, ft-lb) Wastegate control solenoid valve T1: 1.25 (0.1, 0.9) ASSY T2: 6.4 (0.7, 4.7) Vacuum hose T3: 8.3 (0.8, 6.1) Fuel pipe protector LH T4: 19 (1.9, 14.0) Fuel pipe protector RH T5: 25 (2.5, 18.4) O-ring
T (2)
(1)
FU-03455
(1)
O-ring
(2)
Throttle body
FU(H4DOTC)-4
General Description

T1
(4)
T2
T1 (1) (2)
T1
(3)
FU-03083
(1) (2) (3)
Crankshaft position sensor Knock sensor Camshaft position sensor LH
(4)
Camshaft position sensor RH
FU(H4DOTC)-5
General Description
4. FUEL TANK
T1 (28)
(29) (17) (17) (15) (8) (17) (7) (10) (17) (9) (15) (17) (26) (25) (1) (17) (30) (11) (31) (12) (33) (17) (14) (18) T1 (16) (27)
(32) T4 (13)
(19) (2) (20) T4 T3 T3
(3) T4 (21)
(6) (5) (21)
T3 T3 (22)
(23)
(24)
(4)
(34) T3
T2
T2
T3 FU-04002
FU(H4DOTC)-6
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) Fuel tank Fuel tank band RH Fuel tank band LH Fuel delivery tube Fuel return tube Jet pump tube Fuel pump assembly Fuel pump upper plate Fuel pump gasket Fuel level sensor Fuel sub level sensor Fuel sub level sensor upper plate Fuel sub level sensor gasket Fuel filler hose (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) Clamp Evaporation hose A Clip Fuel tank protector LH (Rear) Stopper RH Stopper LH Retainer Heat shield cover Fuel tank protector RH (Front) Fuel tank protector LH (Front) Evaporation hose B Connector Evaporation hose C (28) (29) (30) (31) (32) (33) (34) Evaporation hose D Evaporation pipe Evaporation hose E Evaporation hose F Fuel sub level sensor filter Fuel sub level sensor protector Clip
FU(H4DOTC)-7
General Description
5. FUEL LINE
T2 (28) T1 (30) T6 (23) (38) (39) T6 T2 (23) (23) T2 (22) T2 (23) C (26) (23) T1 (38) (23) (21) (36) (31) (23) (37) (27) (25)
(29) (24)
T2 (19)
(18) T2 (40) (41) (23) (42) (20) (1) (32) (1) (1) T2 (17) (34) (1) (33) (16) C
(1)
(31) T4 B T2
(33) T3 (14)
(15) T5 (1) (1) (12)
T5 (2) (13) (1) (3)
(1)
(13) (35)
T5
(8)
(43)
(13)
(10) (5) (1) (13) (4) (13) T5 T5 (35) T2 D (6) (7) (9)
(11)
FU-03292
FU(H4DOTC)-8
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Clip Fuel delivery hose A Evaporation hose A Fuel return hose A Fuel return hose B Fuel damper holder Fuel damper bracket Fuel delivery hose B Fuel pipe ASSY A Fuel delivery hose C Fuel return hose C Evaporation hose B Clamp Grommet Fuel pipe ASSY B Canister Drain valve (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) Drain filter Canister protector Pressure control solenoid valve Evaporation pipe A Evaporation pipe B Clip Fuel filler pipe Shut valve Gasket Filler ring Fuel filler cap Fuel tank pressure sensor Evaporation pipe protector Connector A Canister hose A Connector B Canister hose B (35) (36) (37) (38) (39) (40) (41) (42) (43) Fuel damper Drain hose Drain hose connector Evaporation hose C Evaporation hose D Retainer Evaporation tube Evaporation hose E Quick connector check cover
Tightening torque:Nm (kgf-m, ft-lb) T1: 4.4 (0.4, 3.2) T2: 7.5 (0.8, 5.5) T3: 8 (0.8, 5.9) T4: 17.5 (1.8, 12.9) T5: 1.25 (0.1, 0.9) T6: 1 (0.1, 0.7)
FU(H4DOTC)-9
General Description
6. FUEL PUMP
(1)
(2) b (5) d (4) a b (2) C
(3)
(5)
(6)
(2) (8) d (10) C (7)
(9)
(12)
(13)
(11)
FU-04004
(1) (2) (3) (4) (5)
(6) (7) (8) (9)
(10) (11) (12) (13)
FU(H4DOTC)-10
General Description
C: CAUTION
FU(H4DOTC)-11
General Description
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER 42099AE000 DESCRIPTION QUICK CONNECTOR RELEASE REMARKS Used for disconnecting quick connector on the fuel delivery hose side of the engine compartment.
ST42099AE000
18371AA000
CONNECTOR REMOVER
Used for disconnecting the quick connector on the fuel return hose of the engine compartment.
ST18371AA000
18353AA000
CLAMP PLIERS
Used for removing and installing the PCV hose. This is a general tool made by the French company CAILLAU. (code) 54.0.000.205 To make this easier to obtain, it has been provided with a tool number.
ST18353AA000
18471AA000
FUEL PIPE ADAPTER
ST18471AA000
FU(H4DOTC)-12
General Description
ILLUSTRATION TOOL NUMBER 1B022XU0 DESCRIPTION SUBARU SELECT MONITOR III KIT REMARKS Used for draining fuel.
ST1B022XU0
FU(H4DOTC)-13
Throttle Body
2. Throttle Body
A: REMOVAL
1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
11) Disconnect the engine coolant hoses from the throttle body.
FU-03814
12) Remove the bolts which secure the throttle body to the intake manifold, and remove the throttle body.
IN-00203
4) Lift up the vehicle. 5) Remove the under cover. 6) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 7) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 8) Disconnect the connectors from the throttle position sensor.
FU-03815
FU-03463
9) Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loosen the clamp which connects the throttle body and duct.
FU-03020
10) Remove the duct from the throttle body.
FU(H4DOTC)-14
Throttle Body
B: INSTALLATION
FU-03815
Tightening torque: T1: 3 Nm (0.3 kgf-m, 2.2 ft-lb) T2: 6.5 Nm (0.7 kgf-m, 4.8 ft-lb)
T2 T1
FU-04029
FU(H4DOTC)-15
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Collect the refrigerant from A/C system. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 4) Release the fuel pressure. <Ref. to FU(H4DOTC)57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 5) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 6) Open the fuel filler lid, and remove the fuel filler cap. 7) Lift up the vehicle. 8) Remove the under cover. 9) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 10) Remove the air intake duct and air cleaner case. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.> 11) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 12) Remove the generator. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 13) Remove the coolant filler tank. <Ref. to CO(H4DOTC)-30, REMOVAL, Coolant Filler Tank.> 14) Disconnect the A/C pressure hoses from A/C compressor. <Ref. to AC-40, REMOVAL, Hose and Pipe.> 15) Disconnect the vacuum hose (A) and the connector (B) from the PCV hose assembly.
16) Remove the connector from the PCV hose assembly.
FU-03899
17) Remove the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold, and loosen the clamp which connects the throttle body and duct.
FU-03020
18) Remove the duct from the throttle body. 19) Disconnect the engine coolant hose from throttle body.
(A)
FU-03814
20) Disconnect the brake booster vacuum hose.

(B) FU-03898
ME-03898
FU(H4DOTC)-16
Intake Manifold
21) Disconnect the PCV hose from the rocker cover. NOTE: Fit the cut out in the ST with the protrusion on the clamp as shown in the figure, unlock the clamp, and disconnect the PCV hose fastened by the clamp. ST 18353AA000 CLAMP PLIERS
25) Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
(A) (B) (C)
FU-00027
26) Disconnect the connector from power steering pump switch.
FU-03116
22) Disconnect the air control hose (A) from the wastegate actuator, and loosen the clamp that holds the turbocharger on the intake duct.
FU-03022 (A)
27) Disconnect the knock sensor connector.
IN-02499
23) Disconnect the bulk head harness connectors from the engine harness connector.
FU-03900
FU-02436
24) Remove the engine harness connector from the engine harness bracket.
FU(H4DOTC)-17
Intake Manifold
28) Disconnect the connector from the secondary air combination valve.
30) Disconnect the connector from the oil flow control solenoid valve.
FU-03901
FU-03903
31) Disconnect the air duct from the secondary air pump, and remove the bolts that install the air duct on the rocker cover LH.
FU-03905
FU-03902
FU(H4DOTC)-18
Intake Manifold
32) Disconnect the connector from ignition coil.
34) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
(A)
ST
(C) (B) FU-03411
FU-04003
33) Disconnect the connector from the front oxygen (A/F) sensor, and remove the engine harness fixed by clip (A) from the rocker cover. (right side only)
(A) Fuel delivery hose (B) Fuel return hose (C) Evaporation hose
35) Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel return pipe as shown in the figure.
(A)
FU-03993
ST
FU-03092
FU(H4DOTC)-19
Intake Manifold
(2) Insert the front side of ST into the quick connector.
B: INSTALLATION
1) Install the intake manifold onto cylinder heads. NOTE: Use a new gasket. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
ST
FU-03113
(3) Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
FU-03085
2) Connect the fuel delivery hose, fuel return hose, and evaporation hose. <Ref. to FU(H4DOTC)-81, INSTALLATION, Fuel Delivery, Return and Evaporation Lines.> NOTE: If fuel hoses or clamps are damaged, replace them with new parts.
FU-03114 (A)
ST
36) Remove the clip and disconnect the evaporation hose from the fuel pipe.
(C) (B) FU-03412
FU-03105
37) Remove the bolts which hold the tumble generator valve assembly onto the cylinder head.
FU-03085
FU(H4DOTC)-20
Intake Manifold
3) Connect the connector to the oil flow control solenoid valve.
6) Connect the connector to the power steering pump switch.
FU-03022
7) Connect the connectors to camshaft position sensor.
FU-03903
4) Connect the connector to the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
(A) (B) (C)
FU-03902 FU-00027
5) Connect the connector to the knock sensor.
FU-03900
FU(H4DOTC)-21
Intake Manifold
8) Connect the connector to the secondary air combination valve.
10) Connect the connector to the ignition coil.
FU-04003 FU-03901
9) Connect the connector from the front oxygen (A/ F) sensor, and install the engine harness with clip (A) to the rocker cover. (right side only)
11) Connect the air duct to the secondary air pump, and install the air duct on the rocker cover. Tightening torque: 9 Nm (0.9 kgf-m, 6.6 ft-lb)
(A)
FU-03993
FU-03905
12) Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.
FU-02436
FU(H4DOTC)-22
Intake Manifold
13) Connect the air control hose (A) to the wastegate actuator, and tighten the clamp that holds the intake duct on the turbocharger. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb)
16) Connect the engine coolant hoses to throttle body.
(A) FU-03814
17) Install the duct to the throttle body.

IN-02499
14) Connect the brake booster vacuum hose.
Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb) 18) Attach the bolts which secure the air by-pass pipe and PCV pipe to the intake manifold. Tightening torque: 6.5 Nm (0.7 kgf-m, 4.8 ft-lb)
ME-03898
15) Connect the PCV hose to the rocker cover. NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS
FU-03028
19) Attach the connector to the PCV hose assembly.
FU-03899 FU-03116
FU(H4DOTC)-23
Intake Manifold
20) Connect the vacuum hose (A) and the connector (B) to the PCV hose assembly.
C: DISASSEMBLY
1) Remove the engine ground terminal from the fuel pipe protector LH, and remove the fuel pipe protector LH from the intake manifold.
(A)
(B) FU-03898
21) Install the A/C pressure hoses. <Ref. to AC-40, INSTALLATION, Hose and Pipe.> 22) Install the coolant filler tank. <Ref. to CO(H4DOTC)-30, INSTALLATION, Coolant Filler Tank.> 23) Install the generator. <Ref. to SC(H4SO)-14, INSTALLATION, Generator.> 24) Install the intercooler. <Ref. to IN(H4DOTC)13, INSTALLATION, Intercooler.> 25) Install the air intake duct and air cleaner case. <Ref. to IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.> <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.> 26) Install the battery. <Ref. to SC(H4SO)-20, INSTALLATION, Battery.> 27) Lift up the vehicle. 28) Install the under cover. 29) Lower the vehicle. 30) Fill engine coolant. <Ref. to CO(H4DOTC)-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 31) Charge the A/C system with refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.> 32) Install the collector cover.
FU-03086
2) Remove the fuel pipe protector RH from the intake manifold.
FU-03087
3) Disconnect the evaporation hose and the connector from the purge control solenoid valve 1, and remove the purge control solenoid valve 1 from the intake manifold.
FU-04030
4) Disconnect the filter assembly.
FU-03030
FU(H4DOTC)-24
Intake Manifold
5) Remove the solenoid valve bracket assembly from the intake manifold, and disconnect the connector from the wastegate control solenoid valve, manifold absolute pressure sensor and purge control solenoid valve 2.
9) Disconnect the connector from the fuel injector and the tumble generator valve assembly.
FU-03088
EC-00219
10) Remove the PCV pipe (A), harness assembly (B) and intake duct (C) from the intake manifold.
(A) (B)
6) Disconnect the evaporation hose of the purge control solenoid valve 2 from the intake duct and fuel pipe assembly. 7) Disconnect the connectors from the throttle position sensor.
(C) FU-03033
11) Remove the bolt which secures the fuel injector pipe LH onto the front side of intake manifold, and disconnect the pressure regulator vacuum hose from the intake manifold.
FU-03463
8) Remove the throttle body from the intake manifold.
FU-04031
FU-03815
FU(H4DOTC)-25
Intake Manifold
12) Remove the bolt which holds fuel injector pipe onto intake manifold. RH side
FU-03109 FU-03089
LH side
15) Remove the bolt which secures fuel injector pipe RH onto the lower side of the intake manifold.
FU-03090
FU-03110
13) Remove the fuel injector. RH side
16) Loosen the clamp which holds the fuel hose to the fuel injector pipe, and then disconnect the fuel hose from pipe.
FU-03094
LH side
FU-03111
17) Remove the fuel injector pipe. 18) Remove the tumble generator valve assembly from the intake manifold.
FU-03091
FU-03039
FU(H4DOTC)-26
Intake Manifold
D: ASSEMBLY
1) Install the tumble generator valve assembly onto intake manifold. NOTE: Use new O-rings. Tightening torque: 8.3 Nm (0.8 kgf-m, 6.1 ft-lb)
5) Tighten the bolts which secure fuel injector pipe onto intake manifold. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-03109
6) Install the fuel injector. RH side

FU-03039
2) Install the fuel injector pipe. 3) Connect fuel hoses to fuel injector pipes on both sides, and secure them with the clamps. Tightening torque: 1.25 Nm (0.1 kgf-m, 0.9 ft-lb)
FU-03094
LH side
FU-03111
4) Tighten the bolts which secure the fuel injector pipe RH to the lower side of the intake manifold. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-03091
FU-03110
FU(H4DOTC)-27
Intake Manifold
7) Tighten the bolts which secure fuel injector pipe onto intake manifold. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb) LH side
9) Install PCV pipe (A), harness assembly (B) and intake duct (C) to the intake manifold. Tightening torque: 6.5 Nm (0.7 kgf-m, 4.8 ft-lb)
(A) (B)
(C) FU-03033 FU-03090
RH side
10) Connect the connector to the fuel injector and the tumble generator valve assembly.
FU-03089
FU-03088
8) Tighten the bolt which holds the fuel injector pipe LH to the front side of the intake manifold, and connect the pressure regulator vacuum hose to the intake manifold. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
11) Install the throttle body to the intake manifold. NOTE: Use new O-rings. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
FU-03815 FU-04031
FU(H4DOTC)-28
Intake Manifold
12) Connect the connector to the throttle position sensor.
14) Connect the connectors to the wastegate control solenoid valve, manifold absolute pressure sensor and purge control solenoid valve 2, and install the solenoid valve bracket assembly to the intake manifold. Tightening torque: T1: 17 Nm (1.7 kgf-m, 12.5 ft-lb) T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-03463
T1
T2
13) Connect the evaporation hose to the purge control solenoid valve 2. NOTE: Connect the evaporation hose as shown in the figure.
EC-02252 (A)
15) Connect the filter assembly.
FU-03030 (c) (B) (a)
(b)
(c)
EC-02201
(A) (B) (a) (b) (c)
Purge control solenoid valve 1 Purge control solenoid valve 2 To intake manifold To intake duct To fuel pipe
FU(H4DOTC)-29
Intake Manifold
16) Connect the evaporation hose and the connector to the purge control solenoid valve 1, and install the purge control solenoid valve 1 to the intake manifold. NOTE: Connect the evaporation hose as shown in the figure.
(A)
17) Install the fuel pipe protector RH to the intake manifold. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-03087
18) Install the fuel pipe protector LH to the intake manifold, and install the engine ground terminal to the fuel pipe protector LH. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
(c) (B)
(a)
(b)
(c)
EC-02201
(A) (B) (a) (b) (c)
FU-03086
E: INSPECTION
Make sure that the fuel pipe and fuel hose are not cracked and that the connections are tight.
FU-04030
FU(H4DOTC)-30


A: REMOVAL
1) Remove the collector cover. 2) Disconnect the ground cable from battery.
IN-00203
3) Remove the generator. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 4) Drain engine coolant. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 5) Disconnect the connectors from the engine coolant temperature sensor.
FU-04032
B: INSTALLATION
FU(H4DOTC)-31


A: REMOVAL
B: INSTALLATION
IN-00203
FU-03811
3) Remove the bolt which installs crankshaft position sensor to cylinder block.
FU-03811
4) Remove the crankshaft position sensor, and then disconnect the connector from it.
FU-00057
FU(H4DOTC)-32


A: REMOVAL
1. CAMSHAFT POSITION SENSOR RH
3) Remove the camshaft position sensor LH.
FU-03520
B: INSTALLATION
IN-00203
3) Disconnect the connector from camshaft position sensor RH. 4) Remove the camshaft position sensor RH from the rear side of the cylinder head.
FU-03906
2. CAMSHAFT POSITION SENSOR LH

IN-00203
2) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.>
FU(H4DOTC)-33
Knock Sensor
7. Knock Sensor
A: REMOVAL
B: INSTALLATION
1) Install the knock sensor to the cylinder block. NOTE: The portion of the knock sensor cord that is pulled out must be positioned at a 60 angle relative to the engine rear. Tightening torque: 24 Nm (2.4 kgf-m, 17.7 ft-lb)
(A)
IN-00203
3) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 4) Disconnect the knock sensor connector.
(A) Front side
60
FU-03826
FU-03437
5) Remove the knock sensor from the cylinder block.

FU-03437
3) Install the intercooler. <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 4) Connect the ground cable to battery.
FU-03825
IN-00203
5) Install the collector cover.
FU(H4DOTC)-34


A: SPECIFICATION
Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to Throttle Body for removal and installation procedure. <Ref. to FU(H4DOTC)-14, REMOVAL, Throttle Body.> <Ref. to FU(H4DOTC)-15, INSTALLATION, Throttle Body.>
FU(H4DOTC)-35

9. Mass Air Flow and Intake Air Temperature Sensor

A: REMOVAL
IN-00203
2) Disconnect the connector from the mass air flow and intake air temperature sensor, and remove the mass air flow and intake air temperature sensor.
FU-01187
B: INSTALLATION
FU(H4DOTC)-36

10.Manifold Absolute Pressure Sensor

A: REMOVAL
IN-00203
3) Disconnect the connector from manifold absolute pressure sensor (A), and remove the filter assembly (B) from intake manifold. 4) Remove the manifold absolute pressure sensor from the solenoid valve bracket.
(A)
(B)
FU-04033
B: INSTALLATION
FU(H4DOTC)-37
Fuel Injector
11.Fuel Injector
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure. <Ref. to FU(H4DOTC)57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
9) Remove the fuel injector.
FU-03094
2. LH SIDE
1) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
IN-00203
4) Open the fuel filler lid, and remove the fuel filler cap. 5) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 6) Remove the fuel pipe protector RH from the intake manifold.
IN-00203
4) Open the fuel filler lid and remove the fuel filler cap. 5) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 6) Remove the engine ground terminal from the fuel pipe protector LH and remove the fuel pipe protector LH from the intake manifold.
FU-03087
7) Disconnect the connector from fuel injector. 8) Remove the bolt which holds fuel injector pipe onto intake manifold.
FU-03086
7) Disconnect the connector from fuel injector.
FU-03089
FU(H4DOTC)-38
Fuel Injector
B: INSTALLATION
1. RH SIDE
FU-03034
FU-03089

FU-03090
9) Remove the fuel injector.
FU-03087
FU-03091
FU(H4DOTC)-39
Fuel Injector
2. LH SIDE
FU-03090
FU-03034
FU-03086
FU(H4DOTC)-40
Tumble Generator Valve Assembly

12.Tumble Generator Valve Assembly

A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(H4DOTC)57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 8.3 Nm (0.8 kgf-m, 6.1 ft-lb)
FU-03039
IN-00203
4) Open the fuel filler lid, and remove the fuel filler cap. 5) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 6) Disconnect the connector from the tumble generator valve assembly.
FU-03093
7) Remove the fuel injector. <Ref. to FU(H4DOTC)-38, REMOVAL, Fuel Injector.> 8) Remove the tumble generator valve assembly from the intake manifold.
FU-03039
FU(H4DOTC)-41
Tumble Generator Valve Actuator

13.Tumble Generator Valve Actuator

A: SPECIFICATION
The tumble generator valve assembly cannot be disassembled. Refer to Tumble Generator Valve Assembly for removal and installation procedures. <Ref. to FU(H4DOTC)-41, REMOVAL, Tumble Generator Valve Assembly.> <Ref. to FU(H4DOTC)-41, INSTALLATION, Tumble Generator Valve Assembly.>
FU(H4DOTC)-42
Tumble Generator Valve Position Sensor

14.Tumble Generator Valve Position Sensor

A: SPECIFICATION
The tumble generator valve assembly cannot be disassembled. Refer to Tumble Generator Valve Assembly for removal and installation procedures. <Ref. to FU(H4DOTC)-41, REMOVAL, Tumble Generator Valve Assembly.> <Ref. to FU(H4DOTC)-41, INSTALLATION, Tumble Generator Valve Assembly.>
FU(H4DOTC)-43
Oil Flow Control Solenoid Valve

15.Oil Flow Control Solenoid Valve

A: REMOVAL
Oil flow control solenoid valve is a unit with front camshaft cap. Refer to Camshaft for removal procedure. <Ref. to ME(H4DOTC)-58, REMOVAL, Camshaft.>
3) Attach the oil return cover and gasket. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb) NOTE: Use a new gasket.
(D) (C) (B)
B: INSTALLATION
Refer to Camshaft for installation procedure. <Ref. to ME(H4DOTC)-59, INSTALLATION, Camshaft.>
(A)
C: DISASSEMBLY
1) Remove the 2 mounting bolts and remove the oil return cover and gasket. 2) Remove the mounting bolt and remove the oil flow control solenoid valve.
FU-03158
(A) (B) (C) (D)
Oil flow control solenoid valve Oil return cover Gasket Front camshaft cap
(D) (C) (B)
(A)
FU-03158
(A) (B) (C) (D)
Oil flow control solenoid valve Oil return cover Gasket Front camshaft cap
D: ASSEMBLY
1) Install the oil flow control solenoid valve. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb) 2) Apply liquid gasket to the two bolts which secure the oil return cover. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent
FU(H4DOTC)-44
Wastegate Control Solenoid Valve

16.Wastegate Control Solenoid Valve

A: REMOVAL
IN-00203
3) Disconnect the connector from the wastegate control solenoid valve (A). 4) Disconnect pressure hose (B) from the wastegate control solenoid valve. 5) Remove the wastegate control solenoid valve from the bracket
(B)
(A)
FU-01192
B: INSTALLATION
FU(H4DOTC)-45


A: REMOVAL
B: INSTALLATION
CAUTION: If lubricant is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protector of front oxygen (A/F) sensor. Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the front oxygen (A/F) sensor. Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft-lb)
IN-00203
4) Remove the air intake duct and air cleaner case. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.> 5) Disconnect the connector from front oxygen (A/ F) sensor.
FU-03994
FU-03235
6) Lift up the vehicle. 7) Remove the under cover. 8) Apply spray-type lubricant or equivalent to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 9) Remove the front oxygen (A/F) sensor. CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.
3) Install the under cover. 4) Lower the vehicle. 5) Connect the connector of front oxygen (A/F) sensor.
FU-03235
6) Install the air intake duct and air cleaner case. <Ref. to IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.> <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.>
FU-03994
FU(H4DOTC)-46

IN-00203
FU(H4DOTC)-47
Rear Oxygen Sensor


A: REMOVAL
7) Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.
IN-00203
FU-03829
3) Lift up the vehicle. 4) Remove clip (A) holding the rear oxygen sensor harness. (AT model) 5) Disconnect the connector from the rear oxygen sensor. AT model
B: INSTALLATION
CAUTION: If lubricant is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protector of rear oxygen sensor.
(A) EX-02368
MT model
Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the rear oxygen sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.5 ft-lb)
EX-02361
6) Apply spray-type lubricant or equivalent to the threaded portion of rear oxygen sensor, and leave it for one minute or more.
FU-03829
3) Affix the rear oxygen sensor with the clip (A). (AT model)
FU(H4DOTC)-48
Rear Oxygen Sensor

4) Connect the connector to rear oxygen sensor. AT model
(A) EX-02368
MT model
EX-02361
5) Lower the vehicle. 6) Connect the ground cable to battery.
IN-00203
FU(H4DOTC)-49
SI-DRIVE (SUBARU Intelligent Drive) Selector

19.SI-DRIVE (SUBARU Intelligent Drive) Selector

A: REMOVAL
B: INSTALLATION
C: INSPECTION
Measure the resistance between SI-DRIVE selector terminals.
5 4 3 2 1
IN-00203
2) Remove the console box. <Ref. to EI-54, REMOVAL, Console Box.> 3) Disconnect the SI-DRIVE selector connector.
FU-03123
Switch position Sport (when turning the SI-DRIVE selector to the left) Intelligent (when pushing the SI-DRIVE selector) Sport Sharp (when turning the SI-DRIVE selector to the right)
Terminal No.
Standard Less than 10 :
2 and 3
0.8 1.2 k:
2.14 3.2 k:
FU-04006
4) Remove the screws which secure the SI-DRIVE selector to the console box.
FU-04007
5) Disconnect the connector from SI-DRIVE selector cover, and remove the SI-DRIVE selector.
FU-04008
FU(H4DOTC)-50
SI-DRIVE (SUBARU Intelligent Drive) S# Switch

20.SI-DRIVE (SUBARU Intelligent Drive) S# Switch

A: REMOVAL
C: INSPECTION
Measure the resistance between SI-DRIVE S# switch terminals.
4 3 2 1
FU-03121
IN-00203
2) Remove the airbag module. <Ref. to AB-14, REMOVAL, Drivers Airbag Module.> WARNING: Always refer to Airbag System before performing service on the airbag modules. <Ref. to AB-4, CAUTION, General Description.> 3) Remove the screws which secure the SI-DRIVE S# switch to the steering wheel, and remove the SIDRIVE S# switch.
Switch position ON (When the SI-DRIVE S# switch is pressed) OFF
Terminal No. 3 and 4
Standard value Less than 10 : 1 M: or more
FU-03122
4) Disconnect the connectors from the SI-DRIVE S# switch.
B: INSTALLATION
FU(H4DOTC)-51


A: REMOVAL
B: INSTALLATION
IN-00203
FU-03416
5) Remove the nuts and bolts which hold the ECM to the bracket.
FU-03417
FU(H4DOTC)-52
Main Relay
22.Main Relay
A: REMOVAL
IN-00203
(A)
FU-02092
FU-02093
B: INSTALLATION
FU(H4DOTC)-53
Fuel Pump Relay

23.Fuel Pump Relay

A: REMOVAL
IN-00203
(A)
FU-02092
FU-02094
B: INSTALLATION
FU(H4DOTC)-54


A: REMOVAL
IN-00203
(A)
FU-02092
FU-02095
B: INSTALLATION
FU(H4DOTC)-55
Fuel Pump Control Unit

25.Fuel Pump Control Unit

A: REMOVAL
5) Disconnect the connector from fuel pump control unit.
B: INSTALLATION
IN-00203
2) Remove the rear quarter trim of the left side. (Wagon model) <Ref. to EI-63, REMOVAL, Rear Quarter Trim.> 3) Peel the trunk side trim of the left side. (Sedan model) 4) Remove the fuel pump control unit. Wagon model
FU-03220
Sedan model
FU-03231
FU(H4DOTC)-56
Fuel
26.Fuel
A: PROCEDURE
(A)
ST
(C) (B) FU-03095
FU-01122
2) Start the engine and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn the ignition switch to OFF. 5) Install the fuse of fuel pump to the main fuse box.

WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. NOTE: If the fuel pump cannot be actuated, refer to DRAINING FUEL (THROUGH THE FUEL FILLER HOSE). <Ref. to FU(H4DOTC)-57, DRAINING FUEL (THROUGH THE FUEL FILLER HOSE), PROCEDURE, Fuel.> Be careful not to let the battery run-out. 1) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
3) Connect ST to the fuel delivery hose. ST 18471AA000 FUEL PIPE ADAPTER 4) Connect the gasoline proof hose to ST and put the end of the hose in the container. 5) Drive the fuel pump and drain the fuel using Subaru Select Monitor. <Ref. to EN(H4DOTC)(diag)55, FUEL PUMP CONTROL (ON/OFF DRIVE), OPERATION, System Operation Check Mode.> CAUTION: Be careful not to spill fuel.

WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. Fuel may remain in the fuel filler pipe. Draining the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (10 or less) before the operation. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 4) Open the fuel filler lid, and remove the fuel filler cap.
FU(H4DOTC)-57
Fuel
5) Drain the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (10 or less). 6) Disconnect the fuel filler hose (A) from the fuel filler pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
(B)
(A) FU-02394
FU(H4DOTC)-58
Fuel Tank
27.Fuel Tank
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Drain fuel. <Ref. to FU(H4DOTC)-57, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 4) Disconnect the ground cable from battery.
8) Remove the connector (A) and clip (B).

(B) (A)
FU-02389
(A)
(A)
(B) IN-00203
FU-01126
5) Remove the rear seat. 6) Remove the service hole cover of fuel pump.
10) Disconnect connector (A) from fuel sub level sensor. 11) Disconnect the quick connector of fuel delivery tube (B) and fuel return tube (C). <Ref. to FU(H4DOTC)-80, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
(A) (C) FU-02387

(B) FU-01127
12) Remove the trunk room trim. (Sedan model) <Ref. to EI-70, REMOVAL, Trunk Room Trim.> 13) Remove the rear quarter trim. (Wagon model) <Ref. to EI-63, WAGON MODEL, REMOVAL, Rear Quarter Trim.>
FU-02388
FU(H4DOTC)-59
Fuel Tank
14) Remove the pipe protector.
20) Lift up the vehicle. 21) Remove the rear exhaust pipe. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> 22) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 23) Remove the heat shield cover and fuel tank protector. 24) Disconnect the connector from the rear ABS wheel speed sensor.
FU-02390
15) Remove the grommet and disconnect the quick connector of the evaporation pipe. <Ref. to FU(H4DOTC)-80, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
FU-02894
FU-02391
16) Remove the rear wheels. 17) Remove the bolts which secure the rear brake hose mounting bracket.
FU-02895
FU-01128
FU-02896
FU-00462
19) Remove the parking brake cable from the parking brake assembly. <Ref. to PB-6, REMOVAL, Parking Brake Assembly (Rear Disc Brake).>
FU(H4DOTC)-60
Fuel Tank
26) Remove the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) Remove the bolts which hold the rear shock absorber to the rear suspension arm.
FU-02393
FU-01132
(A)
(B)
FU-02394
FU-01133
FU-03100
FU-03293
FU-02392
FU(H4DOTC)-61
Fuel Tank
B: INSTALLATION
FU-02393
FU-03293
2) Securely insert the fuel filler hose (A) and evaporation hose (B) into the specified position, then tighten the clamp or clip as shown in the figure.
(B)
FU-02392
(A) FU-02394
(1)
(2)
(3)
L/2 L
FU-00104
FU(H4DOTC)-62
Fuel Tank
6) Install the rear suspension assembly. CAUTION: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) Support the rear suspension assembly, and tighten the bolts which secure the rear suspension assembly to the body. Tightening torque: T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb) T2: 175 Nm (17.8 kgf-m, 129.1 ft-lb)
T1 T1
FU-02895 T1
T1
FU-01150
FU-02896
T2
T2
FU-03101
FU-02894
9) Install the heat shield cover. Tightening torque: 17.5 Nm (1.8 kgf-m, 12.9 ft-lb) 10) Install the fuel tank protector. Tightening torque: Nut: 9 Nm (0.9 kgf-m, 6.6 ft-lb) Bolt: 17.5 Nm (1.8 kgf-m, 12.9 ft-lb) 11) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 12) Install the rear exhaust pipe. <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> 13) Lower the vehicle.
FU-01132
FU(H4DOTC)-63
Fuel Tank
20) Install the trunk room trim. (Sedan model) <Ref. to EI-71, INSTALLATION, Trunk Room Trim.> 21) Install the rear quarter trim. (Wagon model) <Ref. to EI-64, INSTALLATION, Rear Quarter Trim.> 22) Connect connector (A) to the fuel sub level sensor. 23) Connect the quick connector of fuel delivery tube (B) and fuel return tube (C). <Ref. to FU(H4DOTC)-81, INSTALLATION, Fuel Delivery, Return and Evaporation Lines.> NOTE: When connecting, be careful not to reverse the delivery side and return side.
(A) (C) FU-01128
17) Install the rear wheels. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 18) Connect the quick connector of the evaporation pipe. <Ref. to FU(H4DOTC)-81, INSTALLATION, Fuel Delivery, Return and Evaporation Lines.>
(B) FU-01127
(A)
(A)
(B) FU-02391
FU-01126
25) Connect connector (A), and install clip (B).

(B) (A)
T2
T1
FU-02868
FU-02389
FU(H4DOTC)-64
Fuel Tank
FU-02388
FU-02387
28) Install the rear seat. 29) Connect the ground cable to battery.
IN-00203
C: INSPECTION
1) Check that the fuel tank does not have holes, cracks or is damaged in any other way. 2) Check that the fuel pipe and fuel hose are not cracked and those connections are tight.
FU(H4DOTC)-65
Fuel Filler Pipe

28.Fuel Filler Pipe

A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Drain fuel. <Ref. to FU(H4DOTC)-57, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 4) Disconnect the ground cable from battery.
FU-02395
12) Disconnect the fuel filler hose (A) and evaporation hose (B) from the fuel filler pipe.
(B)
(A) FU-02396 IN-00203
5) Open the fuel filler lid, and remove the fuel filler cap. 6) Remove the screws which secure gasket.
(B)
FU-02397
FU-00095
FU(H4DOTC)-66
Fuel Filler Pipe

B: INSTALLATION
1) Open the fuel filler lid. 2) Set the fuel saucer (A) with rubber gasket (C), and insert the fuel filler pipe into hole from the inner side of apron. 3) Align the holes in fuel filler pipe neck and set the cup (B), and tighten the screws. NOTE: If the edges of rubber gasket are folded toward inside, straighten it with a flat tip screwdriver.
4) Securely insert the fuel filler hose (A) and evaporation hose (B) into the specified position, then attach the clamp or clip as shown in the figure. Tightening torque: 2.5 Nm (0.3 kgf-m, 1.8 ft-lb)
(B) (A) (A) FU-02396 (B) (C) (B)
FU-00103
FU-02397
(1)
(2)
(3)
L/2 L
FU-00104
FU(H4DOTC)-67
Fuel Filler Pipe

D: DISASSEMBLY
FU-02398 FU-02395
FU-02399
IN-00203
FU-02400
C: INSPECTION
1) Check that the fuel filler pipe does not have holes or cracks, nor damaged in any way. 2) Make sure that the fuel hose is not cracked and that the connections are tight.
3) Remove the shut valve from the fuel filler pipe. <Ref. to EC(H4DOTC)-18, REMOVAL, Shut Valve.>
FU(H4DOTC)-68
Fuel Filler Pipe

E: ASSEMBLY
1) Install the shut valve to the fuel filler pipe. <Ref. to EC(H4DOTC)-18, INSTALLATION, Shut Valve.> 2) Tighten the nuts which secure the evaporation pipe assembly to the fuel filler pipe. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
FU-02399
FU-02400
FU-02398
FU(H4DOTC)-69
Fuel Pump
29.Fuel Pump
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: Fuel pump assembly consists of fuel pump, fuel filter and fuel level sensor. 1) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Drain fuel. <Ref. to FU(H4DOTC)-57, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 3) Disconnect the ground cable from battery.
FU-02388
7) Disconnect the quick connector of fuel delivery tube, fuel return tube and jet pump tube. <Ref. to FU(H4DOTC)-80, REMOVAL, Fuel Delivery, Return and Evaporation Lines.> 8) Remove the nuts which install fuel pump assembly onto fuel tank.
(B) (C)
(A)
FU-01140
(A) Fuel delivery tube (B) Fuel return tube (C) Jet pump tube
IN-00203
4) Remove the rear seat. 5) Remove the service hole cover.
9) Remove the fuel pump assembly from the fuel tank.
FU-02387
FU(H4DOTC)-70
Fuel Pump
B: INSTALLATION
Install in the reverse order of removal while being careful of the following. Make sure the sealing portion is free from fuel or foreign matter before installation. Install with the protrusion (A) of gasket aimed at the front side of the vehicle. Insert the protrusion (B) of the gasket into the upper plate. (3 places) Align the protrusion (C) of the fuel pump assembly to the cutout in the upper plate. Tighten the nuts to the specified torque in the order as shown in the figure. NOTE: Use a new gasket and retainer. Tightening torque: 4.4 Nm (0.4 kgf-m, 3.2 ft-lb)
1 4 (B) 6 5 (C) 8 (B)
7 (B) 2 (A)
3
FU-02835
C: INSPECTION
Connect the lead harness to the connector terminal of fuel pump, and apply the battery power supply to check whether the pump operates. WARNING: Wipe off fuel completely. Keep the battery as far apart from fuel pump as possible. Be sure to perform the ON/OFF operation on the battery side. Do not run the fuel pump for a long time under non-load condition.
2 1 4 3 6 5
FU-01330
FU(H4DOTC)-71
Fuel Level Sensor


A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: The fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. <Ref. to FU(H4DOTC)-70, REMOVAL, Fuel Pump.> 2) Disconnect the connector from fuel pump bracket. 3) Remove the fuel level sensor and fuel temperature sensor.
(A) (C)
(B) FU-02401
B: INSTALLATION
FU(H4DOTC)-72


A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. 1) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Drain fuel. <Ref. to FU(H4DOTC)-57, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 3) Disconnect the ground cable from battery.
FU-01143
7) Disconnect the quick connector of fuel delivery tube, fuel return tube and jet pump tube. <Ref. to FU(H4DOTC)-80, REMOVAL, Fuel Delivery, Return and Evaporation Lines.> 8) Remove the nuts and bolts which install fuel sub level sensor on fuel tank.
(C) (A)
(B) IN-00203
FU-01144
(A) Jet pump tube (B) Fuel delivery tube (C) Fuel return tube
(A)
(A)
(B)
FU-01126
FU(H4DOTC)-73

B: INSTALLATION
Install in the reverse order of removal while being careful of the following. Make sure the sealing portion is free from fuel or foreign matter before installation. Align protrusion (A) of the gasket to the position shown in the following figure. Align protrusion (B) of the fuel sub level sensor to the cut out in the fuel sublevel sensor upper plate. Tighten the nuts and bolts to the specified torque in the order as shown in the figure. NOTE: Use a new gasket and retainer. Tightening torque: 4.4 Nm (0.4 kgf-m, 3.2 ft-lb)
3 1 5
6 2 4 (A)
FU-02836
(B)
FU-01146
FU(H4DOTC)-74
Fuel Filter
32.Fuel Filter
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. Be careful not to drop or apply any impact to the fuel pump during work. This may deteriorate its performance. NOTE: The fuel filter is built in fuel pump assembly. 1) Remove the fuel pump assembly. <Ref. to FU(H4DOTC)-70, REMOVAL, Fuel Pump.> 2) Remove the fuel level sensor and fuel temperature sensor. <Ref. to FU(H4DOTC)-72, REMOVAL, Fuel Level Sensor.> 3) Disconnect the pump assembly connector from the sub tank bracket assembly.
FU-03851
(A)
FU-03852

FU-03849
4) Cut off the tab holders connecting the sub tank bracket assembly and the sub tank in four locations, and separate the two. CAUTION: Be careful not to damage the sub tank. NOTE: If the O-ring is remaining on the subtank, remove.
FU-03853
FU-03850
FU(H4DOTC)-75
Fuel Filter
8) Lift the two tab holders connecting the pump assembly to the fuel filter using a flat tip screwdriver (with a shaft diameter of approx. 3 mm (0.12 in)), etc., and separate the fuel filter and pump assembly. CAUTION: To prevent damaging the tabs of the pump assembly, wrap the tip of flat tip screwdriver (A), etc. with tape (B).
(B) (A)
B: INSTALLATION
1) Assemble o-ring (A) and spacer (B) to the fuel pump, and attach the pump assembly to the fuel filter. NOTE: Use new O-rings (8 mm (0.31 in) inner diameter). Use a new spacer. Apply gasoline to the o-ring. Insert the pump assembly until a click is heard.
(B) FU-03929
Be careful not to drop or apply any impact to the pump assembly. NOTE: If the spacer and o-ring is remaining on the pump assembly, remove these.
(A)
FU-03859
FU-03927
FU-03853
FU(H4DOTC)-76
Fuel Filter
(A) (A) FU-03851
6) Attach the O-ring (A) to the fuel filter assembly, and attach the subtank to the sub tank bracket assembly.
FU-03860
(A)
NOTE: Use new O-rings (8 mm (0.31 in) inner diameter). Apply gasoline to the o-ring. Insert the pump assembly until a pop is heard.
FU-03861 (A)
FU-03862
FU(H4DOTC)-77
Fuel Filter
FU-03863
FU-03849
9) Install the fuel level sensor and fuel temperature sensor. <Ref. to FU(H4DOTC)-72, INSTALLATION, Fuel Level Sensor.> <Ref. to EC(H4DOTC)13, INSTALLATION, Fuel Temperature Sensor.> 10) Install the fuel pump assembly. <Ref. to FU(H4DOTC)-71, INSTALLATION, Fuel Pump.>
FU(H4DOTC)-78
Fuel Damper
33.Fuel Damper
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. 1) Release the fuel pressure. <Ref. to FU(H4DOTC)57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the fuel damper from fuel delivery hose (A) and fuel return hose (B).
(A)
(B)
FU-03115
B: INSTALLATION
FU(H4DOTC)-79
Fuel Delivery, Return and Evaporation Lines

34.Fuel Delivery, Return and Evaporation Lines

A: REMOVAL
FU-03107
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H4DOTC)57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Remove the floor mat. <Ref. to EI-72, REMOVAL, Floor Mat.> 5) In the engine compartment, disconnect the fuel delivery hoses, fuel return hoses and evaporation hoses. (1) Disconnect the quick connector on the fuel delivery line and return line by pushing the ST in the direction of the arrow. ST 42099AE000 QUICK CONNECTOR RELEASE
(2) Remove the clip and disconnect the evaporation hose from the fuel pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
ST
(A) (C) (B)
FU-03430
6) Remove the canister. <Ref. to EC(H4DOTC)-7, REMOVAL, Canister.> 7) Remove the fuel tank. <Ref. to FU(H4DOTC)59, REMOVAL, Fuel Tank.> 8) Remove the fuel pipe assembly.
FU(H4DOTC)-80

9) Disconnect the quick connector, then disconnect the fuel delivery tube, fuel return tube and jet pump tube. (1) Clean the pipe and connector, if they are covered with dust. (2) To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag etc.
B: INSTALLATION

(A) FU-01333
(B) (A) (C)
(B)
FU-00125
1) Set the new retainer (B) to connector (A).
FU-00124
FU(H4DOTC)-81

2) Push the pipe into the connector completely.

(A) (B)
2. CONNECT FUEL DELIVERY HOSE AND FUEL RETURN HOSE

Connect the fuel delivery hose and fuel return hose to the pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When the amount to be inserted is specified. Type B: When the amount to be inserted is not specified. L1: 2.5r1.5 mm (0.098r0.059 in) L2: 22.5r2.5 mm (0.886r0.098 in) CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel.
(3) (1) L1 L2 (2) L1 FU-03390 (4) (5)
(C)
FU-00126
(A)
(1) (2) (3) (4) (5)

(B) (C)
FU-00127

(1) (2) (3)
L/2 L FU-00129
FU(H4DOTC)-82

C: INSPECTION
FU(H4DOTC)-83


A: INSPECTION
Trouble and possible cause 1. Insufficient fuel supply to injector 1) Fuel pump does not operate. Defective terminal contact Trouble in electromagnetic or electronic circuit parts Decline of fuel pump function Clogged fuel filter Clogged or bent fuel pipe or hose Air is mixed in the fuel system. Clogged or bent air breather tube or pipe. Damaged diaphragm of pressure regulator Corrective action
2) 3) 4) 5) 6) 7)
Inspect contact, especially ground, and tighten it securely. Replace the faulty parts. Replace the fuel pump. Replace the fuel filter. Clean or replace the fuel tank if necessary. Clean, correct or replace the fuel pipe or hose. Inspect or retighten each connection part. Clean, correct or replace the air breather tube or pipe. Replace. Retighten. Replace. Replace. Clean, correct or replace the air breather tube or air vent tube.
3. Gasoline smell inside of compartment Loose joints at air breather tube, air vent tube and fuel filler 1) pipe 2) Defective gasket air tightness on the fuel saucer 3) Inoperative fuel pump modulator or circuit 4. Defective fuel meter indicator 1) Defective operation of fuel level sensor 2) Defective operation of fuel meter 5. Noise 1) Large operation noise or vibration of fuel pump
NOTE: When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. Fill the fuel tank fully to prevent this. In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop to 0C (32F) or less throughout the winter season, use a water removing agent in the fuel system to prevent freezing fuel system and accumulating water. When water is accumulated in fuel filter, fill the water removing agent in the fuel tank. Before using water removing agent, follow the cautions noted on the bottle.
FU(H4DOTC)-84
General Description
A: COMPONENT
1. SECONDARY AIR PUMP
(5)
T1
T2
(3)
(1)
(2)
T1
T1
(4)
T1
(6) EC-02422
(1) (2) (3)
Secondary air pump Clip Secondary air pump bracket
(4) (5) (6)
Secondary air pump cover Harness stay Secondary air pump harness
EC(H4DOTC)-2
General Description
2. SECONDARY AIR COMBINATION VALVE

(4) T1 (6) T1 T1 (7) (2) (4)
a
(5)
(4) (10) T1 (8) T1 (4) (11) T2

a
(1)
(9)
(3)
EC-02423
(1) (2) (3) (4) (5) (6)
Gasket Gasket Gasket Clamp Secondary air pipe RH Secondary air combination valve RH
(7) (8) (9) (10)
Air duct A Air duct B Secondary air combination valve LH Secondary air pipe LH
(11)
Gasket
B: CAUTION
EC(H4DOTC)-3
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 18353AA000 DESCRIPTION CLAMP PLIER REMARKS Used for removing and installing the PCV hose. This is a general tool made by the French company CAILLAU. (code) 54.0.000.205 To make this easier to obtain, it has been provided with a tool number.
ST18353AA000
EC(H4DOTC)-4


A: REMOVAL
The front catalytic converter is integrated into the center exhaust pipe (front). Refer to Center Exhaust Pipe for removal procedures. <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.>
B: INSTALLATION
The front catalytic converter is integrated into the center exhaust pipe (front). Refer to Center Exhaust Pipe for installation procedures. <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.>
C: INSPECTION
EC(H4DOTC)-5


A: REMOVAL
The rear catalytic converter is integrated into the center exhaust pipe (rear). Refer to Center Exhaust Pipe for removal procedures. <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.>
B: INSTALLATION
The rear catalytic converter is integrated into the center exhaust pipe (rear). Refer to Center Exhaust Pipe for installation procedures. <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.>
C: INSPECTION
EC(H4DOTC)-6
Canister
4. Canister
A: REMOVAL
IN-00203
(B)
EC-02080
(A)
(C) (A) EC-02079
EC(H4DOTC)-7
Canister
B: INSTALLATION
EC-02080
C: INSPECTION
EC(H4DOTC)-8


A: REMOVAL
1. PURGE CONTROL SOLENOID VALVE 1
3) Remove the solenoid valve bracket assembly from intake manifold.
EC-00219
IN-00203
3) Remove the bolts which install purge control solenoid valve 1 to the intake manifold, and disconnect the connector from the purge control solenoid valve 1.
4) Disconnect the connector from purge control solenoid valve 2. 5) Disconnect the evaporation hose from the intake duct and fuel pipe assembly. 6) Remove the purge control solenoid valve 2 from the solenoid valve bracket assembly.
EC-02266
EC-02424
4) Disconnect the evaporation hose from the intake manifold and fuel pipe assembly.

IN-00203
EC(H4DOTC)-9

B: INSTALLATION
Install in the reverse order of removal. NOTE: Connect the evaporation hose as shown in the figure.
(A)

Install in the reverse order of removal. NOTE: Connect the evaporation hose as shown in the figure.
(A)
(c) (B) (c) (B) (a) (b)
(a)
(b)
(c) (c) EC-02201
EC-02201
(A) (B) (a) (b) (c)
(A) (B) (a) (b) (c)
EC-02266 EC-02424
EC(H4DOTC)-10

Tightening torque: T1: 17 Nm (1.7 kgf-m, 12.5 ft-lb) T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
T1
T2
EC-02252
C: INSPECTION
EC(H4DOTC)-11
Fuel Level Sensor


A: REMOVAL
For removal procedures, refer to the FU (H4DOTC) section. <Ref. to FU(H4DOTC)-72, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
For installation procedures, refer to the FU (H4DOTC) section. <Ref. to FU(H4DOTC)-72, INSTALLATION, Fuel Level Sensor.>
EC(H4DOTC)-12


A: REMOVAL
The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to Fuel Level Sensor for removal procedure. <Ref. to FU(H4DOTC)-72, REMOVAL, Fuel Level Sensor.>
(A)
EC-02083
(A) Fuel temperature sensor
B: INSTALLATION
The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to Fuel Level Sensor for installation procedure. <Ref. to FU(H4DOTC)-72, INSTALLATION, Fuel Level Sensor.>
(A)
EC-02083
EC(H4DOTC)-13


A: REMOVAL
For removal procedures, refer to the FU (H4DOTC) section. <Ref. to FU(H4DOTC)-73, REMOVAL, Fuel Sub Level Sensor.>
B: INSTALLATION
For installation procedures, refer to the FU (H4DOTC) section. <Ref. to FU(H4DOTC)-74, INSTALLATION, Fuel Sub Level Sensor.>
EC(H4DOTC)-14

9. Fuel Tank Pressure Sensor

A: REMOVAL
C: INSPECTION
IN-00203
3) Open the fuel filler lid, and remove the fuel filler cap. 4) Lift up the vehicle. 5) Disconnect the connector from the fuel tank pressure sensor. 6) Disconnect the pressure hose from the fuel tank pressure sensor. 7) Remove the fuel tank pressure sensor along with the bracket.
EC-02084
B: INSTALLATION
EC-02084
EC(H4DOTC)-15


A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from the battery.
B: INSTALLATION
C: INSPECTION
IN-00203
(A) (B)
(B) (C)
EC-02086
EC-02087
EC(H4DOTC)-16
Drain Filter
11.Drain Filter
A: SPECIFICATION
Canister is a non-disassembled part, so do not remove the drain filter from canister. Refer to Canister for removal and installation procedures. <Ref. to EC(H4DOTC)-7, REMOVAL, Canister.> <Ref. to EC(H4DOTC)-8, INSTALLATION, Canister.>
EC(H4DOTC)-17
Shut Valve
12.Shut Valve
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Remove the fuel filler pipe. <Ref. to FU(H4DOTC)-66, REMOVAL, Fuel Filler Pipe.> 2) Disconnect the evaporation hose from the shut valve.
B: INSTALLATION
EC-02089
C: INSPECTION
EC-02088
EC-02089
EC(H4DOTC)-18
Drain Valve
13.Drain Valve
A: SPECIFICATION
Canister is a non-disassembled part, so do not remove the drain valve from canister. Refer to Canister for removal and installation procedures. <Ref. to EC(H4DOTC)-7, REMOVAL, Canister.> <Ref. to EC(H4DOTC)-8, INSTALLATION, Canister.>
EC(H4DOTC)-19
PCV Hose Assembly

14.PCV Hose Assembly

A: REMOVAL
CAUTION: Do not remove unless the PCV hose, diagnostics connector and PCV valve are damaged. 1) Remove the collector cover. 2) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 3) Remove the secondary air combination valve RH. <Ref. to EC(H4DOTC)-22, SECONDARY AIR COMBINATION VALVE RH, REMOVAL, Secondary Air Combination Valve.> 4) Fit the depression in the ST with the protrusion on the clamp to unlock. 5) Remove the PCV hose assembly. ST 18353AA000 CLAMP PLIER
B: INSTALLATION
1) Install the PCV hose assembly, then lock by fitting the ST on the clamp protrusion. NOTE: Use a new clamp. ST 18353AA000 CLAMP PLIER
EC-02388
2) Install the secondary air combination valve RH. <Ref. to EC(H4DOTC)-23, SECONDARY AIR COMBINATION VALVE RH, INSTALLATION, Secondary Air Combination Valve.> 3) Install the intake manifold. <Ref. to FU(H4DOTC)-20, INSTALLATION, Intake Manifold.> 4) Install the collector cover.
EC-02388
EC(H4DOTC)-20
Secondary Air Pump

15.Secondary Air Pump

A: REMOVAL
B: INSTALLATION
IN-00203
EC-02370
3) Disconnect the connector (A) and air duct (B) from secondary air pump.
C: INSPECTION
(A) (B)
EC-02193
4) Remove the clip (A) which holds the harness on the harness stay and remove the bolts (B) which holds the secondary air pump on the vehicle.
(A)
(B)
EC-02404
5) Remove the secondary air pump.
EC(H4DOTC)-21
Secondary Air Combination Valve

16.Secondary Air Combination Valve

A: REMOVAL
1. SECONDARY AIR COMBINATION VALVE LH
2. SECONDARY AIR COMBINATION VALVE RH

IN-00203
IN-00203
3) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 4) Disconnect the connector from the secondary air combination valve LH. 5) Disconnect the air duct A. 6) Remove the secondary air pipe LH. 7) Remove the secondary air combination valve LH.
3) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 4) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 5) Disconnect the air duct A. 6) Remove the secondary air pipe RH. 7) Remove the secondary air combination valve RH.
(B) (C) (D) (E) (A)
(B)
b
(C) (F) (F)
EC-02213
(D)
b
(E) (B)
a
(G) (A) EC-02407
(A) (B) (C) (D) (E) (F) (G)
Secondary air combination valve LH Clamp Air duct A Gasket Air duct B Secondary air pipe LH Gasket
(A) (B) (C) (D) (E) (F)
Secondary air combination valve RH Clamp Air duct A Gasket Secondary air pipe RH Gasket
EC(H4DOTC)-22

B: INSTALLATION
1. SECONDARY AIR COMBINATION VALVE LH
Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: T1: 9 Nm (0.9 kgf-m, 6.6 ft-lb) T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
2. SECONDARY AIR COMBINATION VALVE RH

Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: T: 9 Nm (0.9 kgf-m, 6.6 ft-lb)
(B) (C) (D) T (A) T
(B)
b
(C)
(E)
(D) T1
b
(F) (G) (A) T2 EC-02390
(F)
EC-02425
(E) T1 (B)
a
(A) Secondary air combination valve RH (B) Clamp (C) (D) (E) (F) Air duct A Gasket Secondary air pipe RH Gasket
(A) (B) (C) (D) (E) (F) (G)
Secondary air combination valve LH Clamp Air duct A Gasket Air duct B Secondary air pipe LH Gasket
C: INSPECTION
Check the air duct and pipe for looseness.
EC(H4DOTC)-23

EC(H4DOTC)-24
General Description
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
T1 (3) (1) (2) (3) (5) (6) T2 (4)
T4 (7) (5) T2
(13)
(10) (9)
T3
(11) (12)
(8)
IN-02209
(1) (2) (3) (4) (5) (6)
Mass air flow and intake air temperature sensor Air cleaner case (rear) Clip Air intake boot Clamp Air cleaner element
(7) (8) (9) (10) (11) (12) (13)
Air cleaner case (front) Air intake duct Clip Resonator chamber Cushion Spacer Cushion
Tightening torque:Nm (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 2.5 (0.3, 1.8) T3: 6 (0.6, 4.4) T4: 7.5 (0.8, 5.5)
IN(H4DOTC)-2
General Description
INTAKE (INDUCTION)
2. INTAKE DUCT
(14) (14)
(2)
(1) (15) (14)
T2 (4) (16)
T3 (3)
T1
(2)
(5) (9) T3
(8)
T1 (12) T1 (11)
(6)
(7)
(13)
(10)
IN-02297
(1) (2) (3) (4) (5) (6) (7)
PCV hose ASSY A Intake manifold Solenoid valve bracket ASSY Intake duct Engine harness ASSY Vacuum hose Vacuum hose
(8) (9) (10) (11) (12) (13) (14)
PCV pipe Vacuum hose Air by-pass pipe Clamp Vacuum hose Brake booster vacuum hose Clamp
(15) (16)
PCV hose ASSY B Solenoid valve bracket
Tightening torque:Nm (kgf-m, ft-lb) T1: 6.5 (0.7, 4.8) T2: 17 (1.7, 12.5) T3: 19 (1.9, 14.0)
IN(H4DOTC)-3
General Description
INTAKE (INDUCTION)
3. INTERCOOLER
T2
(5) (6) (3) T2
(2)
T1
(4) (1)
T2 (8)
(7)
IN-02466
(1) (2) (3) (4)
Intercooler O-ring Air by-pass valve O-ring
(5) (6) (7) (8)
Spacer Cushion Intercooler stay Clip
IN(H4DOTC)-4
General Description
INTAKE (INDUCTION)
4. TURBOCHARGER
(1) T1 T3
(2)
T4 (3)
(7) (8) T2 (9) (10)
(6) (2) (2) (2) (5) T2 (4)
T5
(11)
(2)
(9)
(12) T6
IN-02443
(1) (2) (3) (4) (5) (6) (7)
Oil inlet pipe Metal gasket Turbocharger Water pipe Clip Engine coolant hose Gasket
(8) (9) (10) (11) (12)
Oil outlet pipe Clip Oil outlet hose Turbocharger bracket RH Turbocharger bracket LH
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 7.8 (0.8, 5.8) T3: 16 (1.6, 11.8) T4: 20 (2.0, 14.8) T5: 23 (2.3, 17.0) T6: 33 (3.4, 24.3)
IN(H4DOTC)-5
General Description
INTAKE (INDUCTION)
B: CAUTION
IN(H4DOTC)-6
Air Cleaner Element

INTAKE (INDUCTION)

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Be sure to use SUBARU genuine air cleaner element depending on the engine type when replacing the air cleaner elements. Using other air cleaner element may affect the engine performance. NOTE: Check that there are no foreign objects in the air cleaner case.
C: INSPECTION
IN-00203
Replace if excessively damaged or dirty.
2) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 3) Disconnect the connector (A) from mass air flow and intake air temperature sensor. 4) Remove the clip (B) from the air cleaner case.
(A) (B)
(B)
IN-02254
5) Open the air cleaner case, and remove the air cleaner element.
IN-02255
IN(H4DOTC)-7
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. NOTE: When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.
IN-00203
3) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 4) Disconnect the connector (A) from mass air flow and intake air temperature sensor. 5) Loosen the clamp (B) which connects the air intake boot and intake duct. 6) Remove the clip (C) from the air cleaner case.
(A) (C) (B)
IN-00220
Tightening torque: Bolt (A) 6 Nm (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
(B)
(C)
(B) (A) IN-02211
IN-02210
7) Remove the air cleaner case (rear) and air intake boot. 8) Remove the air cleaner element. 9) Remove the bolts (A) and nuts (B) which secure the air cleaner case (front) to the body.
(B)
IN-02491 (A) IN-02211
C: INSPECTION
IN(H4DOTC)-8
Air Intake Duct

INTAKE (INDUCTION)
4. Air Intake Duct

A: REMOVAL
IN-00217
B: INSTALLATION
C: INSPECTION
1) Check for cracks or loose connections. 2) Inspect that no foreign objects in the air intake duct.
IN(H4DOTC)-9
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to Air Cleaner Case for removal procedure. <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to Air Cleaner Case for installation procedure. <Ref. to IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H4DOTC)-10
Intake Duct
INTAKE (INDUCTION)
6. Intake Duct
A: REMOVAL
IN-00203
3) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 4) Remove the sensor, engine harness and fuel pipe attached to the intake manifold. <Ref. to FU(H4DOTC)-24, DISASSEMBLY, Intake Manifold.> 5) Remove the intake duct from intake manifold.
IN-02505
B: INSTALLATION
IN-02505
IN(H4DOTC)-11
Intercooler
INTAKE (INDUCTION)
7. Intercooler
A: REMOVAL
1) Remove the collector cover. 2) Disconnect the air by-pass pipe (A) and vacuum hose (B) from the air by-pass valve. 3) Loosen the clamp (C) which connects the air intercooler and intake duct.
6) Remove the brake booster vacuum hose from the clip (A), and remove the intercooler stay.
(A)
IN-02478 (A) (B)
(C)
IN-02301
4) Remove the bolts which secure the intercooler to the turbocharger.
IN-02467
5) Remove the bolts which secure the intercooler to the intercooler stay, and remove the intercooler.
IN-02468
IN(H4DOTC)-12
Intercooler
INTAKE (INDUCTION)
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use new O-rings. Be careful not to pinch the O-ring. Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
C: DISASSEMBLY
1) Remove the air by-pass valve from intercooler.
IN-02094
D: ASSEMBLY
Assemble in the reverse order of disassembly. NOTE: Use new O-rings. Be careful not to pinch the O-ring. Tightening torque: 6.5 Nm (0.7 kgf-m, 4.8 ft-lb)
IN-02303
IN-02467
IN-02094
E: INSPECTION
IN-02468
IN-02304
IN(H4DOTC)-13
Turbocharger
INTAKE (INDUCTION)
8. Turbocharger
A: REMOVAL
12) Disconnect the air control hose (A), and loosen the clamp holding the turbocharger to the intake duct.
(A)
IN-02499
13) Remove the oil inlet pipe from the turbocharger.

IN-00203
4) Lift up the vehicle. 5) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 6) Lower the vehicle. 7) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 8) Remove the center exhaust pipe. <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 9) Lower the vehicle. 10) Separate the turbocharger joint pipe from turbocharger.
IN-02500
14) Disconnect the engine coolant hose from the water pipe.
IN-02456
IN-02497
15) Disconnect the oil outlet hose from the oil outlet pipe.
11) Disconnect the engine coolant hose which is connected to coolant filler tank.
IN-02310
IN-02506
16) Take out the turbocharger from engine compartment.
IN(H4DOTC)-14
Turbocharger
INTAKE (INDUCTION)
17) Remove the turbocharger stay.
3) Connect the engine coolant hoses to the water pipe.
(A) (A)
(B)
IN-02373 IN-02456
(A) To cylinder head RH (B) To cylinder block RH
4) Install the oil inlet pipe to turbocharger. Tightening torque: T1: 5 Nm (0.5 kgf-m, 3.7 ft-lb) T2: 16 Nm (1.6 kgf-m, 11.8 ft-lb) T3: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
T2 T1
B: INSTALLATION
1) Install the turbocharger stay. Tightening torque: T1: 33 Nm (3.4 kgf-m, 24.3 ft-lb) T2: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
T2
T1 T3
(A) (A) (B) IN-02501
IN-02377
5) Connect the air control hose (A) and install the turbocharger to the intake duct. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb)
(A) To cylinder head RH (B) To cylinder block RH
2) Connect the oil outlet hose to the oil outlet pipe.

(A)
IN-02499
IN-02310
IN(H4DOTC)-15
Turbocharger
INTAKE (INDUCTION)
6) Connect the engine coolant hose which is connected to the coolant filler tank.
C: INSPECTION
Check that there are no oil leaks or water leaks from the pipe attachment section. Check for cracks or loose connections.
IN-02506
7) Install the joint pipe to turbocharger. NOTE: Replace the gasket with a new part. Tightening torque: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
IN-02497
8) Lift up the vehicle. 9) Install the center exhaust pipe. <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> 10) Lower the vehicle. 11) Install the intercooler. <Ref. to IN(H4DOTC)13, INSTALLATION, Intercooler.> 12) Fill engine coolant. <Ref. to CO(H4DOTC)-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 13) Connect the ground cable to battery.
IN-00203
IN(H4DOTC)-16
Air By-pass Valve

INTAKE (INDUCTION)
9. Air By-pass Valve

A: REMOVAL
1) Remove the collector cover. 2) Disconnect the air by-pass pipe (A) and vacuum hose (B) from the air by-pass valve (C). 3) Remove the air by-pass valve (C) from the intercooler.
(C)
(A)
(B)
IN-02477
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use new O-rings. Be careful not to pinch the O-ring. Tightening torque: 6.5 Nm (0.7 kgf-m, 4.8 ft-lb)
(C)
(A)
(B)
IN-02477
(A) Air by-pass pipe (B) Vacuum hose (C) Air by-pass valve
IN(H4DOTC)-17
Air By-pass Valve

INTAKE (INDUCTION)
IN(H4DOTC)-18
General Description
MECHANICAL
A: SPECIFICATION
Model Cylinder arrangement Valve system mechanism Bore Stroke Displacement Compression ratio Compression pressure (at 200 300 rpm) Number of piston rings Engine mm (in) cm3 (cu in) kPa (kg/cm2, psi) 2.5 L Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Belt driven, double overhead camshaft, 4-valve/cylinder 99.5 79.0 (3.92 3.11) 2,457 (149.94) 8.4 981 1,177 (10 12, 142 171) Pressure ring: 2, Oil ring: 1 ATDC 5 BTDC 35 ABDC 65 ABDC 25 BBDC 55 ATDC 5 0.20r0.02 (0.0079r0.0008) 0.35r0.02 (0.0138r0.0008) 750r100 800r100 (MT model) 825r100 (AT model) 1o3o2o4 12r10/750 17r10/750
Intake valve timing
Exhaust valve timing Valve clearance
Max. retard Min. advance Max. retard Close Min. advance Open Close Intake mm (in) Exhaust Open No load rpm A/C ON
Idling speed [at neutral position on MT, or P or N position on AT] Ignition order Ignition timing BTDC/rpm
MT model AT model
ME(H4DOTC)-2
General Description
MECHANICAL
NOTE: OS: Oversize

Belt tension adjuster
US: Undersize
Protrusion of adjuster rod Bending limit Thrust clearance mm (in) mm (in) mm (in) Standard Intake Standard mm (in) Exhaust Standard Front mm (in) Standard Center, rear mm (in) Standard mm (in) mm (in) mm (in) Intake Exhaust Standard Standard mm (in) mm (in) Standard Standard 5.2 6.2 (0.205 0.244) 0.020 (0.00079) or less 0.068 0.116 (0.0027 0.0047) 46.55 46.65 (1.833 1.837) 46.75 46.85 (1.841 1.844) 37.946 37.963 (1.4939 1.4946) 29.946 29.963 (1.1790 1.1796) 0.037 0.072 (0.0015 0.0028) 0.035 (0.0014) 0.3 (0.012) 127.5 (5.02) 90 0.6 1.4 (0.024 0.055) 1.2 1.8 (0.047 0.071) 6.000 6.012 (0.2362 0.2367) 15.8 16.2 (0.622 0.638) 1.0 1.4 (0.039 0.055) 1.3 1.7 (0.051 0.067) 5.955 5.970 (0.2344 0.2350) 5.945 5.960 (0.2341 0.2346) 0.030 0.057 (0.0012 0.0022) 0.040 0.067 (0.0016 0.0026) 104.4 (4.110) 104.65 (4.1201) 47.32 (1.863) 2.5, 2.1 mm (0.083 in) or less 205 235 (20.9 24.0, 46.1 52.8)/36.0 (1.417) 426 490 (43.4 50.0, 95.8 110)/26.5 (1.043) 34.959 34.975 (1.3763 1.3770) 34.994 35.016 (1.3777 1.3786) 0.019 0.057 (0.0007 0.0022) 0.025 (0.0098) 0.1 (0.004) 201.0 (7.91) 99.505 99.515 (3.9175 3.9179) 99.495 99.505 (3.9171 3.9175) 0.015 (0.0006) 0.010 (0.0004) 0.010 0.010 (0.00039 0.00039) To 100.005 (3.9372) 99.505 99.515 (3.9175 3.9179) 99.495 99.505 (3.9171 3.9175) 99.745 99.765 (3.9270 3.9278) 99.995 100.015 (3.9368 3.9376)
Camshaft
Cam lobe height Journal O.D.
Cylinder head
Journal clearance Surface warping limit (Mating surface with cylinder block) Grinding limit Standard height Seating angle Contacting width Inside diameter Protrusion above head Head edge thickness Stem outer diameter
Valve seat
mm (in)
Valve guide
Valve Valve stem gap Overall length Free length Squareness Valve spring Tension/spring height
Intake Exhaust Intake mm (in) Exhaust mm (in) mm (in) Standard mm (in) Intake Exhaust
Intake Exhaust
mm (in)
Set N (kgf, lb)/mm (in) Lift Outer diameter Inner diameter (cylinder head) Valve lifter clearance Surface warping limit (Mating surface with cylinder head) Grinding limit Standard height Cylinder inner diameter mm (in) Standard mm (in) Standard mm (in) Standard mm (in) mm (in) mm (in)
Valve lifter
Cylinder block
Piston
A B Taper mm (in) Standard Out-of-roundness mm (in) Standard Piston clearance mm (in) Standard Cylinder inner diameter boring limit (diameter) mm (in) A Standard B Outer diameter mm (in) 0.25 (0.0098) OS 0.50 (0.0197) OS mm (in) Standard
ME(H4DOTC)-3
General Description
MECHANICAL
Standard clearance between piston and piston pin Degree of fit Top ring Standard Ring closed gap mm (in) Second ring Standard Oil ring Standard Top ring Standard Ring groove gap mm (in) Second ring Standard Bend or twist per 100 mm (3.94 in) mm (in) Service limit in length Thrust clearance mm (in) Standard Oil clearance mm (in) Standard Standard 0.03 (0.0012) US Bearing size mm (in) (Thickness at center) 0.05 (0.0020) US 0.25 (0.0098) US Clearance between piston pin and mm (in) Standard bushing Bending limit mm (in) Out-of-roundness mm (in) Crank pin Cylindricality mm (in) Grinding limit (dia.) mm (in) Out-of-roundness mm (in) Crank journal Cylindricality mm (in) Grinding limit (dia.) mm (in) Standard 0.03 (0.0012) US Crank pin outer diameter mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Standard 0.03 (0.0012) US Crank journal outer mm (in) diameter 0.05 (0.0020) US 0.25 (0.0098) US Thrust clearance mm (in) Standard Oil clearance mm (in) Standard Standard 0.03 (0.0012) US #1, #3 0.05 (0.0020) US Bearing size 0.25 (0.0098) US (Thickness at center) Standard mm (in) #2, #4, 0.03 (0.0012) US #5 0.05 (0.0020) US 0.25 (0.0098) US mm (in) Standard 0.004 0.008 (0.0002 0.0003) Piston pin must be fitted into position with thumb at 20C (68F). 0.20 0.25 (0.0079 0.0098) 0.37 0.52 (0.015 0.0203) 0.20 0.50 (0.0079 0.0197) 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028) 0.1 (0.0039) 0.070 0.330 (0.0028 0.0130) 0.017 0.045 (0.0007 0.0018) 1.490 1.502 (0.0587 0.0591) 1.504 1.512 (0.0592 0.0595) 1.514 1.522 (0.0596 0.0599) 1.614 1.622 (0.0635 0.0639) 0 0.022 (0 0.0009) 0.035 (0.0014) 0.003 (0.0001) 0.004 (0.0002) To 51.750 (2.0374) 0.005 (0.0002) 0.006 (0.0002) To 59.758 (2.3527) 51.984 52.000 (2.0466 2.0472) 51.954 51.970 (2.0454 2.0461) 51.934 51.950 (2.0447 2.0453) 51.734 51.750 (2.0368 2.0374) 59.992 60.008 (2.3619 2.3625) 59.962 59.978 (2.3607 2.3613) 59.942 59.958 (2.3599 2.3605) 59.742 59.758 (2.3520 2.3527) 0.030 0.115 (0.0012 0.0045) 0.010 0.030 (0.0004 0.0012) 1.998 2.011 (0.0787 0.0792) 2.017 2.020 (0.0794 0.0795) 2.027 2.030 (0.0798 0.0799) 2.127 2.130 (0.0837 0.0839) 2.000 2.013 (0.0787 0.0793) 2.019 2.022 (0.0795 0.0796) 2.029 2.032 (0.0799 0.0800) 2.129 2.132 (0.0838 0.0839)
Piston pin
Piston ring
Connecting rod
Bearing of large end
Crankshaft
Main bearing
ME(H4DOTC)-4
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(19) (1) (2) T3 T4 (3) T2 (19) T3 (20) T8 (21) (7) (8) T7 T2 T8 T7 (14) (21) (17) T7 (11) (13) T2 T8 (20) (10) T3 (19) T1 T8 T6 (23) T2 T2 (9) T5 (6) (5) (4)
T2
(12)
T1
(16) (22) T9 (18) T2
(15)
T2 T2 ME-03933
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Timing belt cover No. 2 RH Timing belt guide (MT model) Crank sprocket Timing belt cover No. 2 LH Tensioner bracket Automatic belt tension adjuster ASSY Belt idler (A) Exhaust cam sprocket RH Intake cam sprocket RH Intake cam sprocket LH Exhaust cam sprocket LH
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)
Timing belt Belt idler No. 2 Belt idler (B) Timing belt cover LH Front belt cover Timing belt cover RH Crank pulley (MT model) Timing belt guide (MT model) O-ring Actuator cover Crank pulley (AT model) Belt idler (C)
Tightening torque:Nm (kgf-m, ft-lb) T1: 3.4 (0.3, 2.5) T2: T3: T4: T5: T6: T7: T8: 5 (0.5, 3.7) 6.4 (0.7, 4.7) 9.75 (1.0, 7.2) 24.5 (2.5, 18.1) 25 (2.5, 18.4) 39 (4.0, 28.8) <Ref. to ME(H4DOTC)-56, INSTALLATION, Cam Sprocket.>
T9: <Ref. to ME(H4DOTC)-44, INSTALLATION, Crank Pulley.>
ME(H4DOTC)-5
General Description
MECHANICAL

T7 (1)
T2 (2) (6) T2
T5 T6 (8) T5 (28) T3 (4) (7) (5) (10) (12) (3) T1 (9) (31) T2 (27)
T6 (30) T2
(13)
(14)
(29) (11) T2 (9) (8) (15) (31) (14) (27) (26) T6 (30) (27) (17) (12) (20) (18) (29) T3 (11) T1 T5 (22) T7 ME-03696 T7 T6 (19) T5 (25) (21) (16) (6) T2 (32) (24) T4 (23)
ME(H4DOTC)-6
General Description
MECHANICAL
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Rocker cover RH Rocker cover gasket RH Front camshaft cap RH Intake camshaft cap RH Intake camshaft RH Oil flow control solenoid valve Exhaust camshaft cap RH Gasket Oil return cover Exhaust camshaft RH Cylinder head bolt Oil seal Cylinder head RH Cylinder head gasket Cylinder head LH Intake camshaft LH Exhaust camshaft LH (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) Front camshaft cap LH Intake camshaft cap LH Exhaust camshaft cap LH Rocker cover gasket LH Rocker cover LH Oil filler cap Oil filler duct O-ring Oil pipe LH Gasket Oil pipe RH Stud bolt Union screw with filter (with protrusion) Union screw without filter (without protrusion) (32) Gasket
Tightening torque:Nm (kgf-m, ft-lb) T1: <Ref. to ME(H4DOTC)-65, INSTALLATION, Cylinder Head.> T2: 8 (0.8, 5.9) T3: <Ref. to ME(H4DOTC)-59, INSTALLATION, Camshaft.> T4: 6.4 (0.7, 4.7) T5: <Ref. to ME(H4DOTC)-59, INSTALLATION, Camshaft.> T6: 29 (3.0, 21.4) T7: <Ref. to ME(H4DOTC)-59, INSTALLATION, Camshaft.>
ME(H4DOTC)-7
General Description
MECHANICAL
(1) (3)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(2)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(12) (4) (10) (6) (12) (4) (10) (6) (7) (8) (9) (7) (8) (9)
ME-03077
(1) (2) (3) (4)
Exhaust valve Intake valve Cylinder head Valve spring seat
(5) (6) (7) (8)
Intake valve oil seal Valve spring Retainer Retainer key
(9) (10) (11) (12)
Valve lifter Exhaust valve oil seal Intake valve guide Exhaust valve guide
ME(H4DOTC)-8
General Description
MECHANICAL
4. CYLINDER BLOCK
T5 T2 (5) T11 (33) T2 (33) (8) (7) (30) (10) (29) T2 (3) T2 (28) T10 (11) (14) (3) (27) (4) (10) (30) T9 T10 (34) (10) (18) T3 (19) (17) T8 T4 (16) (13) (26) T2 (25) T2 (15) T6 T2 T11 (3) (4) (12) (29) T2 (19) (10) T6 (2) (4) (9) (10) T6 T2 T6 (1) T10 (6) (32) T2
(23) T1 (31)
T2 (24)
(20) (22) (21) T7
ME-03959
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)
Oil pressure switch Cylinder block RH Service hole plug Gasket Oil separator cover Water by-pass pipe Oil pump Front oil seal Rear oil seal O-ring Service hole cover Cylinder block LH Water pump Baffle plate Oil cooler Oil cooler pipe Connector
(18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33)
Oil strainer Gasket Oil pan Drain plug Drain plug gasket Oil level gauge guide Oil filter Gasket Water pump hose Nipple Seal Washer Seal washer O-ring Engine rear hanger Oil pump seal
(34)
Water pump sealing
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 6.4 (0.7, 4.7) T3: 10 (1.0, 7.2) T4: First 12 (1.2, 8.9) Second 12 (1.2, 8.9) T5: T6: T7: T8: T9: T10: T11: 16 (1.6, 11.8) 25 (2.5, 18.4) 44 (4.5, 32.5) 54 (5.5, 40) 69 (7.0, 50.9) 70 (7.1, 51.6) <Ref. to ME(H4DOTC)-78, INSTALLATION, Cylinder Block.>
ME(H4DOTC)-9
General Description
MECHANICAL

(1) T2 (5) (4) (6) (2) T2
(10) (9) (3) (12) (13) (10) (8) T1 (11) (14) (15) (13) (14) (11) T1 (13) (8) (16) (13) (7) (12) (6) (5)
(7)
(10)
(10)
(9) (19) (18) (17) (18) (17) ME-02437
(1) (2) (3) (4) (5) (6) (7) (8)
Flywheel (MT model) Ball bearing (MT model) Reinforcement (AT model) Drive plate (AT model) Top ring Second ring Oil ring Piston
(9) (10) (11) (12) (13) (14) (15) (16)
Piston pin Snap ring Connecting rod bolt Connecting rod Connecting rod bearing Connecting rod cap Crankshaft Woodruff key
(17) (18) (19)
Crankshaft bearing #1, #3 Crankshaft bearing #2, #4 Crankshaft bearing #5
ME(H4DOTC)-10
General Description
MECHANICAL
6. ENGINE MOUNTING
(1)
T1
T2
T1
T2
ME-03547
(1)
ME(H4DOTC)-11
General Description
MECHANICAL
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. Be careful not to let oil, grease or engine coolant contact the timing belt, clutch disc and flywheel. All removed parts, if to be reused, should be reinstalled in the original positions and directions. Bolts, nuts and washers should be replaced with new parts as required. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. Lift up or lower the vehicle when necessary. Make sure to support the correct positions.
ME(H4DOTC)-12
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 498267600 DESCRIPTION CYLINDER HEAD TABLE REMARKS Used for replacing valve guides. Used for removing and installing valve spring.
ST-498267600
498457000
ENGINE STAND ADAPTER RH
ST-498457000
498457100
ENGINE STAND ADAPTER LH
ST-498457100
498497100
CRANKSHAFT STOPPER
Used for removing and installing the flywheel and drive plate.
ST-498497100
ME(H4DOTC)-13
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 498747300 DESCRIPTION PISTON GUIDE REMARKS Used for installing the cup to the wheel cylinder piston.
ST-498747300
498857100
VALVE OIL SEAL GUIDE
Used for press-fitting of intake and exhaust valve guide oil seals.
ST-498857100
499017100
PISTON PIN GUIDE
Used for installing piston pin, piston and connecting rod.
ST-499017100
499037100
ST-499037100
499097700
PISTON PIN REMOVER ASSY
Used for removing piston pin.
ST-499097700
ME(H4DOTC)-14
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499207400 DESCRIPTION CAM SPROCKET WRENCH REMARKS Used for removing and installing exhaust cam sprocket.
ST-499207400
499977500
CAM SPROCKET WRENCH
Used for removing and installing intake cam sprocket.
ST-499977500
499587200
ST-499587200
499597100
ST-499597100
499718000
VALVE SPRING REMOVER
Used for removing and installing valve spring.
ST-499718000
ME(H4DOTC)-15
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 18251AA020 DESCRIPTION VALVE GUIDE ADJUSTER REMARKS Used for installing intake and exhaust valve guides.
ST18251AA020
499767200
VALVE GUIDE REMOVER
Used for removing valve guides.
ST-499767200
499767400
VALVE GUIDE REAMER
ST-499767400
499817100
ENGINE STAND
Stand used for engine disassembly and assembly. Used together with the ENGINE STAND ADAPTER RH (498457000) & LH (498457100).
ST-499817100
499977100
CRANK PULLEY WRENCH
Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (MT model)
ST-499977100
ME(H4DOTC)-16
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499977400 DESCRIPTION CRANK PULLEY WRENCH REMARKS Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (AT model)
ST-499977400
499987500
CRANKSHAFT SOCKET
ST-499987500
499587100
OIL SEAL INSTALLER
Used for installing oil pump oil seal.
ST-499587100
499587600
OIL SEAL INSTALLER
Used for installing camshaft oil seal.
ST-499587600
499597200
OIL SEAL GUIDE
Used for installing camshaft oil seal. Used together with the OIL SEAL INSTALLER (499587600).
ST-499597200
ME(H4DOTC)-17
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 498277200 DESCRIPTION STOPPER SET REMARKS Used for installing automatic transmission assembly to engine.
ST-498277200
42099AE000
Used for disconnecting quick connector of the engine compartment.
ST42099AE000
18371AA000
CONNECTOR REMOVER
Used for disconnecting the quick connector on the fuel return hose of the engine compartment.
ST18371AA000
18353AA000
CLAMP PLIERS
Used for removing and installing the PCV hose. This tool is made by the French company CAILLAU. (code) 54.0.000.205 To make it easier to obtain, it has been provided with a tool number.
ST18353AA000
1B022XU0
ST1B022XU0
ME(H4DOTC)-18
General Description
MECHANICAL
2. GENERAL TOOL
TOOL NAME Compression gauge Timing light Vacuum gauge Oil pressure gauge Fuel pressure gauge REMARKS Used for measuring compression. Used for measuring ignition timing. Used for measuring intake manifold vacuum. Used for measuring engine oil pressure. Used for measuring fuel pressure.
E: PROCEDURE
It is possible to conduct the following service procedures with engine on vehicle, however, the procedures described in this section are based on the condition that the engine is removed from vehicle. V-belt Timing belt Camshaft Cylinder head
ME(H4DOTC)-19
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) Remove the collector cover. 2) After warming-up the engine, turn the ignition switch to OFF. 3) Make sure that the battery is fully charged. 4) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 5) Remove all the spark plugs. <Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.> 6) Fully open the throttle valve. 7) Check the starter motor for satisfactory performance and operation. 8) Secure the compression gauge tightly against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long. 9) Crank the engine by the starter motor, and read the maximum value on the gauge when the needle of gauge is steady.
ME-03009
10) Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (fully open throttle): Standard: 981 1,177 kPa (10 12 kgf/cm2, 142 171 psi) Difference between cylinders: 49 kPa (0.5 kgf/cm2, 7 psi) or less 11) After inspection, install the related parts in the reverse order of removal.
ME(H4DOTC)-20
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the following item: (1) Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the engine idle speed using Subaru Select Monitor. <Ref. to EN(H4DOTC)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> 4) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF) Idle speed [No load and gear in neutral, or P, N range]: 750r100 rpm 5) Check the idle speed when loaded. (Turn the A/ C switch to ON and operate the compressor for at least one minute before measurement.) Idle speed [A/C ON and gear in neutral or P or N range]: 800r100 rpm (MT model) 825r100 rpm (AT model) NOTE: Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to the General On-board Diagnosis Table under Engine Control System. <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
ME(H4DOTC)-21
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement.
2. METHOD WITH TIMING LIGHT

1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Stop the engine, and turn the ignition switch to OFF. 4) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 5) Disconnect the connectors of the mass air flow and intake air temperature sensor. 6) Remove the air cleaner case and element. 7) Connect the timing light to the power wire of #1 ignition coil. 8) Install the connectors of air cleaner case, element, and the mass air flow and intake air temperature sensor. 9) Start the engine, turn the timing light to the crank pulley, and check the ignition timing by means of crank pulley indicator. Ignition timing [BTDC/rpm]: 12r10/750 (MT model) 17r10/750 (AT model) If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
1. METHOD WITH SUBARU SELECT MONITOR

1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the ignition timing using Subaru Select Monitor. <Ref. to EN(H4DOTC)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> Ignition timing [BTDC/rpm]: 12r10/750 (MT model) 17r10/750 (AT model) If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
ME(H4DOTC)-22

MECHANICAL

A: INSPECTION
1) Remove the collector cover. 2) Warm up the engine. 3) Disconnect the brake booster vacuum hose from the intake manifold, and then install the vacuum gauge. 4) Keep the engine at idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below.
ME-00801
Vacuum pressure (at idling, A/C OFF): Less than 70.6 kPa (530 mmHg, 20.85 inHg) (MT model) Less than 68.0 kPa (510 mmHg, 20.08 inHg) (AT model)
Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than normal position. This tendency Leakage around intake manifold gasket, or disconnected becomes more evident as engine temperature rises. or damaged vacuum hose 2. Needle intermittently drops to position lower than normal position. Leakage around cylinder 3. Needle drops suddenly and intermittently from normal position. Sticky valve 4. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 5. Needle vibrates above and below normal position in narrow range. Defective ignition system
ME(H4DOTC)-23
Engine Oil Pressure

MECHANICAL

A: INSPECTION
1) Remove the collector cover. 2) Disconnect the ground cable from the battery.
6) Start the engine, and measure the oil pressure.
ME-03698
IN-00203
3) Remove the oil pressure switch. <Ref. to LU(H4SO)-20, REMOVAL, Oil Pressure Switch.> 4) Connect the oil pressure gauge to cylinder block. 5) Connect the ground cable to battery.
Oil pressure: Standard 98 kPa (1.0 kgf/cm2, 14 psi) or more (at 600 rpm) 294 kPa (3.0 kgf/cm2, 43 psi) or more (at 5,000 rpm) If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. <Ref. to LU(H4SO)-24, INSPECTION, Engine Lubrication System Trouble in General.> If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. <Ref. to LU(H4SO)-24, INSPECTION, Engine Lubrication System Trouble in General.> NOTE: Standard value is based on an engine oil temperature of 80C (176F). 7) After measuring the oil pressure, install the oil pressure switch. <Ref. to LU(H4SO)-20, INSTALLATION, Oil Pressure Switch.>
IN-00203
ME(H4DOTC)-24
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
CAUTION: Before removing the fuel pressure gauge, release the fuel pressure. Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. NOTE: If the fuel pressure is out of specification, check or replace the pressure regulator and pressure regulator vacuum hose. 1) Remove the collector cover. 2) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid and remove the fuel filler cap. 4) Disconnect the fuel delivery hose from the fuel damper, and connect the fuel pressure gauge.
ME-03899
5) Start the engine. 6) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Fuel pressure: Standard 284 314 kPa (2.9 3.2 kgf/cm2, 41 46 psi) 7) After connecting the pressure regulator vacuum hose, measure the fuel pressure. NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Fuel pressure: Standard 230 260 kPa (2.35 2.65 kgf/cm2, 33 38 psi)
ME(H4DOTC)-25
Valve Clearance
MECHANICAL
8. Valve Clearance
A: INSPECTION
NOTE: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Disconnect the ground cable from the battery.
11) When inspecting #2 and #4 cylinders (1) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> (2) Remove the secondary air pump. <Ref. to EC(H4DOTC)-21, REMOVAL, Secondary Air Pump.> (3) Remove the ignition coil. <Ref. to IG(H4DOTC)-7, REMOVAL, Ignition Coil.> (4) Place a suitable container under the vehicle. (5) Disconnect the PCV hose from the rocker cover LH. NOTE: For the PCV hose affixed with the clamp, fit the depression in the ST with the protrusion of the clamp as shown in the figure below, unlock the clamp and disconnect. ST 18353AA000 CLAMP PLIERS
IN-00203
4) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 5) Remove the bolt which secures timing belt cover RH. 6) Lift up the vehicle. 7) Remove the under cover. 8) Loosen the remaining bolts which secure timing belt cover RH, then remove the timing belt cover. 9) Lower the vehicle. 10) When inspecting #1 and #3 cylinders (1) Remove the air cleaner case. <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.> (2) Remove the ignition coil. <Ref. to IG(H4DOTC)-7, REMOVAL, Ignition Coil.> (3) Place a suitable container under the vehicle. (4) Disconnect the PCV hose from the rocker cover RH. NOTE: For the PCV hose affixed with the clamp, fit the depression in the ST with the protrusion of the clamp as shown in the figure below, unlock the clamp and disconnect. ST 18353AA000 CLAMP PLIERS
ME-03630
(6) Remove the bolts, then remove the rocker cover LH. 12) Turn the crank pulley clockwise until the round mark and arrow mark on the cam sprocket are set to position shown in the figure. NOTE: Turn the crankshaft using socket wrench.
ME-03171
ME-03630
(5) Remove the bolts, then remove the rocker cover RH.
ME(H4DOTC)-26
Valve Clearance
MECHANICAL
13) Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter. Lift up the vehicle, and then measure the exhaust valve clearances. If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. Valve clearance: Intake 0.20r0.02 mm (0.0079r0.0008 in) Exhaust 0.35r0.02 mm (0.0138r0.0008 in)
(2) Set the round mark and arrow mark on cam sprocket to the position shown in the figure, and measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances.
ME-03173
(3) Set the round mark and arrow mark on cam sprocket to the position shown in the figure, and measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances.
(A)
ME-00019
14) If necessary, adjust the valve clearance. <Ref. to ME(H4DOTC)-28, ADJUSTMENT, Valve Clearance.> 15) Further turn the crank pulley clockwise and then measure the valve clearances again. (1) Set the round mark and arrow mark on cam sprocket to the position shown in the figure, and measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances.
ME-03174
16) After inspection, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket. Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS
ME-03172 ME-03630
ME(H4DOTC)-27
Valve Clearance
MECHANICAL
B: ADJUSTMENT
NOTE: Adjustment of valve clearance should be performed while engine is cold. 1) Measure all the valve clearances. <Ref. to ME(H4DOTC)-26, INSPECTION, Valve Clearance.> NOTE: Record each valve clearance after measurement.
ME-00024
2) Remove the camshaft. <Ref. to ME(H4DOTC)58, REMOVAL, Camshaft.> 3) Remove the valve lifter. 4) Measure the thickness of valve lifter using micrometer.
ME-00025
5) Select a valve lifter of suitable thickness from the following table using the measured valve clearance and valve lifter thickness, and install it. NOTE: Use a new valve lifter.
Unit: mm (in) Intake valve: S = (V + T) 0.20 (0.0079) Exhaust valve: S = (V + T) 0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used
Part No. 13228 AB102 13228 AB112 13228 AB122 13228 AB132 13228 AB142 13228 AB152 13228 AB162 13228 AB172 13228 AB182 13228 AB192 13228 AB202 13228 AB212 13228 AB222 13228 AB232 13228 AB242 13228 AB252 13228 AB262 13228 AB272 13228 AB282 13228 AB292 13228 AB302 13228 AB312 13228 AB322 13228 AB332 13228 AB342 13228 AB352 13228 AB362 13228 AB372 13228 AB382 13228 AB392 13228 AB402 13228 AB412 13228 AB422 13228 AB432 13228 AB442 13228 AB452 13228 AB462 13228 AB472 13228 AB482 13228 AB492 13228 AB502 13228 AB512 13228 AB522 13228 AB532 13228 AB542 13228 AB552 13228 AB562 13228 AB572 13228 AB582 13228 AB592
Thickness mm (in) 4.68 (0.1843) 4.69 (0.1846) 4.70 (0.1850) 4.71 (0.1854) 4.72 (0.1858) 4.73 (0.1862) 4.74 (0.1866) 4.75 (0.1870) 4.76 (0.1874) 4.77 (0.1878) 4.78 (0.1882) 4.79 (0.1886) 4.80 (0.1890) 4.81 (0.1894) 4.82 (0.1898) 4.83 (0.1902) 4.84 (0.1906) 4.85 (0.1909) 4.86 (0.1913) 4.87 (0.1917) 4.88 (0.1921) 4.89 (0.1925) 4.90 (0.1929) 4.91 (0.1933) 4.92 (0.1937) 4.93 (0.1941) 4.94 (0.1945) 4.95 (0.1949) 4.96 (0.1953) 4.97 (0.1957) 4.98 (0.1961) 4.99 (0.1965) 5.00 (0.1969) 5.01 (0.1972) 5.02 (0.1976) 5.03 (0.1980) 5.04 (0.1984) 5.05 (0.1988) 5.06 (0.1992) 5.07 (0.1996) 5.08 (0.2000) 5.09 (0.2004) 5.10 (0.2008) 5.11 (0.2012) 5.12 (0.2016) 5.13 (0.2020) 5.14 (0.2024) 5.15 (0.2028) 5.16 (0.2031) 5.17 (0.2035)
ME(H4DOTC)-28
Valve Clearance
MECHANICAL
Part No. 13228 AB602 13228 AB612 13228 AB622 13228 AB632 13228 AB642 13228 AB652 13228 AB662 13228 AB672 13228 AB682 13228 AB692 13228 AB702 13228 AB712 13228 AB722 13228 AB732 13228 AB742 13228 AB752 13228 AB762 13228 AB772 13228 AB782 13228 AB792 13228 AB802 13228 AB812 13228 AB822 13228 AB832 13228 AB842 13228 AB852 13228 AB862 13228 AB872 13228 AB882 13228 AB892 13228 AB902 13228 AB912 13228 AB922 13228 AB932 13228 AB942 13228 AB952 13228 AB962 13228 AB972 13228 AB982 13228 AB992 13228 AC002 13228 AC012 13228 AC022 13228 AC032 Thickness mm (in) 5.18 (0.2039) 5.19 (0.2043) 5.20 (0.2047) 5.21 (0.2051) 5.22 (0.2055) 5.23 (0.2059) 5.24 (0.2063) 5.25 (0.2067) 5.26 (0.2071) 5.27 (0.2075) 4.38 (0.1724) 4.40 (0.1732) 4.42 (0.1740) 4.44 (0.1748) 4.46 (0.1756) 4.48 (0.1764) 4.50 (0.1771) 4.52 (0.1780) 4.54 (0.1787) 4.56 (0.1795) 4.58 (0.1803) 4.60 (0.1811) 4.62 (0.1819) 4.64 (0.1827) 4.66 (0.1835) 5.29 (0.2083) 5.31 (0.2091) 5.33 (0.2098) 5.35 (0.2106) 5.37 (0.2114) 5.39 (0.2122) 5.41 (0.2123) 5.43 (0.2138) 5.45 (0.2146) 5.47 (0.2154) 5.49 (0.2161) 5.51 (0.2169) 5.53 (0.2177) 5.55 (0.2185) 5.57 (0.2193) 5.59 (0.2201) 5.61 (0.2209) 5.63 (0.2217) 5.65 (0.2224)
6) Install the camshaft. <Ref. to ME(H4DOTC)-59, INSTALLATION, Camshaft.> 7) Install the cam sprocket. <Ref. to ME(H4DOTC)56, INSTALLATION, Cam Sprocket.> 8) Install the timing belt. <Ref. to ME(H4DOTC)-50, TIMING BELT, INSTALLATION, Timing Belt.> 9) Measure all valves for valve clearance again at this time. If the valve clearance is not correct, repeat the procedure over again from the first step. 10) After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket. Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS
ME-03630
ME(H4DOTC)-29
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift. 2) Open the front hood fully and support with the front hood stay. 3) Remove the collector cover. 4) Collect the refrigerant from A/C system. <Ref. to AC-22, Refrigerant Recovery Procedure.> 5) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 6) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 7) Open the fuel filler lid, and remove the fuel filler cap. 8) Remove the air intake duct and air cleaner case. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.> 9) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 10) Remove the radiator from vehicle. <Ref. to CO(H4DOTC)-20, REMOVAL, Radiator.> 11) Remove the coolant filler tank. <Ref. to CO(H4DOTC)-30, REMOVAL, Coolant Filler Tank.> 12) Disconnect the A/C pressure hoses from A/C compressor. <Ref. to AC-40, REMOVAL, Hose and Pipe.> 13) Disconnect the bulkhead harness connectors from the engine harness connectors.
15) Disconnect the following connectors and terminals. (1) Generator connector and terminal
ME-03081
(2) A/C compressor connector
ME-03082
(3) Secondary air pump connector
ME-03638
FU-02436
14) Remove the engine harness connectors from the engine harness brackets.
ME-03898
ME(H4DOTC)-30
Engine Assembly
MECHANICAL
(2) Heater inlet and outlet hoses
23) Disconnect the ground cable on the engine side.
ME-03701
17) Remove the power steering pump. (1) Remove the front side belts. <Ref. to ME(H4DOTC)-41, FRONT SIDE BELT, REMOVAL, V-belt.> (2) Disconnect the power steering pump switch connector.
ME-03702
24) Remove the bolts and nuts which hold the lower side of transmission to the engine. AT model
AT-03238
MT model
FU-03022
(3) Remove the power steering pump from the engine. <Ref. to PS-44, REMOVAL, Oil Pump.>
MT-00077
25) Remove the nuts which hold the engine mount to the front crossmember.
ME-03083
(4) Place the power steering pump on the right side wheel apron. 18) Lift up the vehicle. 19) Remove the center exhaust pipe. <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 20) Remove the turbocharger. <Ref. to IN(H4DOTC)-14, REMOVAL, Turbocharger.> 21) Remove the joint pipe and front exhaust pipe. <Ref. to EX(H4DOTC)-11, REMOVAL, Joint Pipe.> <Ref. to EX(H4DOTC)-5, REMOVAL, Front Exhaust Pipe.> 22) Lift up the vehicle.
ME-03703
26) Lower the vehicle.
ME(H4DOTC)-31
Engine Assembly
MECHANICAL
27) Separate the clutch release fork from the release bearing. (6MT model) (1) Remove the clutch operating cylinder from the transmission. (2) Remove the plug using a 10 mm hexagon wrench.
28) Separate the torque converter clutch from drive plate. (AT model) (1) Remove the service hole plug. (2) Insert the wrench into the crank pulley bolt and rotate the crank pulley to remove the bolts which hold torque converter clutch to drive plate.
ME-00042
(3) Screw-in the 6 mm dia. bolt into the release fork shaft to remove.
ME-00044
(A)
(B)
AT-03877
ME-00043 (A)
(A) Release fork shaft (B) Bolt
(4) Raise the release fork, unlock the release bearing tab, then remove the release fork. NOTE: Step (4) is required to avoid interference with the engine when removing the engine from the transmission.
ST
(C) (B) ME-03907
ME(H4DOTC)-32
Engine Assembly
MECHANICAL
31) Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel return pipe as shown in the figure.
32) Remove the clip and disconnect the evaporation hose from the fuel pipe.
FU-03105
ST
FU-03092
(2) Insert the front side of ST into the quick connector.
LU-00222
34) Support the transmission with a garage jack. CAUTION: Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
FU-03113
ST
(3) Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
(B)
(A)
ME-00215
ST
FU-03114
ME(H4DOTC)-33
Engine Assembly
MECHANICAL
35) Separation of engine and transmission CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. (1) Remove the starter. <Ref. to SC(H4SO)-6, REMOVAL, Starter.> (2) Attach the ST to the torque converter clutch case. (AT model) ST 498277200 STOPPER SET
36) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. (3) Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model) (4) Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 37) Remove the engine mounting from the engine.
B: INSTALLATION
1) Install the clutch release fork and bearing to the transmission. (6MT model) (1) Use a flat tip screwdriver to remove the release bearing from the clutch cover.
ST ME-00217
(3) Remove the bolts which hold the upper side of the transmission to the engine. AT model
ME-00051
(2) Install the release bearing to the transmission. (3) Install the release fork into the release bearing tab.
(A)
ME-00491
MT model
(B)
ME-02591
(A) Release fork (B) Release bearing

MT-01524
ME(H4DOTC)-34
Engine Assembly
MECHANICAL
(4) Apply grease to the specified areas. Grease: Spline part NICHIMOLY N-130 or equivalent Shaft part KOPR-KOTE or equivalent
(6) Tighten the plugs. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
ME-02592
2) Install the engine mounting onto the engine. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb) 3) Apply a small amount of grease to splines of main shaft. (MT model) Grease: NICHIMOLY N-130 or equivalent 4) Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 5) Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) AT model
(A)
(B)
CL-00304
(A) Spline (B) Shaft
(5) Insert the release shaft to release fork. NOTE: Allow the cutout portion of release shaft to come into contact with the spring pin.
(B) (C) (A)
ME-00491
MT model
ME-00054
(A) Release fork (B) Release shaft (C) Spring pin
MT-01524
ME(H4DOTC)-35
Engine Assembly
MECHANICAL
6) Remove the lifting device and wire ropes.
11) Install the torque converter clutch to drive plate. (AT model) (1) Insert the wrench into the crank pulley bolt and rotate the crank pulley to tighten the bolts which hold torque converter clutch to drive plate. NOTE: Be careful not to drop bolts into the torque converter clutch case. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
LU-00222
7) Remove the garage jack. 8) Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
T1
ME-00044
T2
(2) Fit the plug to service hole. 12) Install the power steering pump. (1) Install the power steering pump. Tightening torque: Refer to COMPONENT of Power Steering for the tightening torque. <Ref. to PS-3, COMPONENT, General Description.>
AT-03878
9) Remove the ST from the torque converter clutch case. (AT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET
ME-00037
(2) Connect the power steering pump switch connector.

ST ME-00217
10) Install the starter. <Ref. to SC(H4SO)-6, INSTALLATION, Starter.>
FU-03022
(3) Install and adjust the front side belt. <Ref. to ME(H4DOTC)-42, FRONT SIDE BELT, INSTALLATION, V-belt.>
ME(H4DOTC)-36
Engine Assembly
MECHANICAL
13) Lift up the vehicle. 14) Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) AT model
18) Install the center exhaust pipe. <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> 19) Connect the ground cable. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
AT-03238
ME-03702
MT model
20) Lower the vehicle. 21) Connect the following hoses. (1) Fuel delivery hose, fuel return hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose 22) Connect the following connectors and terminals. (1) Generator connector and terminal
MT-00077
15) Tighten the nuts which hold the engine mount to the crossmember. NOTE: Make sure that the engine mount nuts (A) and locator (B) are securely installed. Tightening torque: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
Tightening torque: 15 Nm (1.5 kgf-m, 11.1 ft-lb) (2) A/C compressor connector (3) Secondary air pump connector 23) Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.
FU-02436
(B) (A)
(A) (B) ME-03704
16) Install the joint pipe and front exhaust pipe. <Ref. to EX(H4DOTC)-6, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-11, INSTALLATION, Joint Pipe.> 17) Install the turbocharger. <Ref. to IN(H4DOTC)15, INSTALLATION, Turbocharger.>
24) Install the intercooler. <Ref. to IN(H4DOTC)13, INSTALLATION, Intercooler.> 25) Install the A/C pressure hoses. <Ref. to AC-40, INSTALLATION, Hose and Pipe.> 26) Install the radiator. <Ref. to CO(H4DOTC)-21, INSTALLATION, Radiator.> 27) Install the coolant filler tank. <Ref. to CO(H4DOTC)-30, INSTALLATION, Coolant Filler Tank.>
ME(H4DOTC)-37
Engine Assembly
MECHANICAL
28) Install the air cleaner case and air intake duct. <Ref. to IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.> <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.> 29) Install the battery. <Ref. to SC(H4SO)-20, INSTALLATION, Battery.> 30) Fill engine coolant. <Ref. to CO(H4DOTC)-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 31) Charge the A/C system with refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.> 32) Check the ATF level and replenish it if necessary. (AT model) <Ref. to 5AT-28, INSPECTION, Automatic Transmission Fluid.> 33) Install the collector cover. 34) Remove the front hood stay, and close the front hood. 35) Lower the vehicle from lift.
C: INSPECTION
1) Check that pipes, hoses, connectors and clamps are installed firmly. 2) Check that the engine coolant is at specified level. 3) Check that the ATF is at specified level. (AT model) 4) Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.
ME(H4DOTC)-38
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H4DOTC)30, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine assembly.
B: INSTALLATION
C: INSPECTION
ME(H4DOTC)-39

MECHANICAL

A: PROCEDURE
1) After removing the engine from body, secure it to ST in the following procedure. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND
ST2 ST1 ST3 ME-00057
2) In this section the procedures described under each index are all connected and stated in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.
ME(H4DOTC)-40
V-belt
MECHANICAL
12.V-belt
A: REMOVAL
NOTE: Perform the work with the engine installed to body when replacing a single part.
2. REAR SIDE BELT

1) Remove the front side belts. <Ref. to ME(H4DOTC)-41, FRONT SIDE BELT, REMOVAL, V-belt.> 2) Loosen the lock nut (A). 3) Loosen the slider bolt (B).
1. FRONT SIDE BELT

1) Remove the collector cover. 2) Remove the air intake duct. <Ref. IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 3) Remove the collector cover bracket. to
(B)
(A)
ME-00060
4) Remove the rear side belt. 5) Remove the belt tensioner.
ME-03084
4) Loosen the bolt (A). 5) Loosen the slider bolt (B). 6) Remove the front side belt (C).
(B) (C) ME-00061
(A)
ME-00059
ME(H4DOTC)-41
V-belt
MECHANICAL
B: INSTALLATION
1. FRONT SIDE BELT
CAUTION: When reusing the front side belt, wipe off dust and water with cloth. Do not use the front side belt if there is any oil, grease or coolant on the belt. Be careful not to rub the belt end surface with bare hands; exposed core may cause injury. 1) Wipe off any dust, oil and water on the groove of each pulley with cloth. 2) Install the front side belt (C), and adjust the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(H4DOTC)-43, INSPECTION, V-belt.> 3) Tighten the bolt (A). 4) Tighten the slider bolt (B). Tightening torque: Bolt (A): 25 Nm (2.5 kgf-m, 18.4 ft-lb) Slider bolt (B): 8 Nm (0.8 kgf-m, 5.9 ft-lb)
(B) (C)
2. REAR SIDE BELT

CAUTION: When reusing the rear side belt, wipe off dust and water with cloth. Do not use the rear side belt if there is any oil, grease or coolant on the belt. Be careful not to rub the belt end surface with bare hands; exposed core may cause injury. 1) Wipe off any dust, oil and water on the groove of each pulley with cloth. 2) Install the belt tensioner. 3) Install a rear side belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(H4DOTC)-43, INSPECTION, V-belt.> 4) Tighten the lock nut (A). Tightening torque: Lock nut (A): 23 Nm (2.3 kgf-m, 17.0 ft-lb)
(B)
(A)
ME-00060
(A)
ME-00059
5) Install the front side belt. <Ref. to ME(H4DOTC)42, FRONT SIDE BELT, INSTALLATION, V-belt.>
5) Install the collector cover bracket. T1: 8.5 Nm (0.9 kgf-m, 6.3 ft-lb) T2: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T1
T2 ME-03947
6) Install the air intake duct. <Ref. to IN(H4DOTC)9, INSTALLATION, Air Intake Duct.> 7) Install the collector cover.
ME(H4DOTC)-42
V-belt
MECHANICAL
C: INSPECTION
1) Replace the belts, if crack, fraying or wear is found. 2) Check the belt tension and adjust it if necessary by changing the generator installing position and idler pulley installing position. Belt tension (with belt tension gauge): (A) When installing new parts: 640 780 N (65 80 kgf, 144 175 lbf) At inspection: 490 640 N (50 65 kgf, 110 144 lbf) (B) When installing new parts: 650 750 N (66 76 kgf, 146 169 lbf) At inspection: 350 450 N (36 46 kgf, 78 101 lbf)
(A)
Belt tension (without belt tension gauge) (A) When installing new parts: 7 9 mm (0.276 0.354 in) At inspection: 9 11 mm (0.354 0.433 in) (B) When installing new parts: 7.5 8.5 mm (0.295 0.335 in) At inspection: 9.0 10.0 mm (0.354 0.394 in)
(C) P/S GEN A/C
(A) (B)
I/P C/P GEN A/C (B)
P/S
PM-00002
I/P C/P PM-00154
Front side belt Rear side belt Crank pulley Generator pulley Power steering oil pump pulley A/C compressor pulley Idler pulley
(A) (B) (C) C/P GEN P/S A/C I/P
Front side belt Rear side belt 98 N (10 kgf, 22 lbf) Crank pulley Generator pulley Power steering oil pump pulley A/C compressor pulley Idler pulley
ME(H4DOTC)-43
Crank Pulley
MECHANICAL
13.Crank Pulley
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 2) Use the ST to lock the crank pulley, and remove the crank pulley bolts. ST 499977100 CRANK PULLEY WRENCH (MT MODEL) ST 499977400 CRANK PULLEY WRENCH (AT MODEL)
B: INSTALLATION
1. AT MODEL
1) Install the crank pulley. 2) Use the ST to lock the crank pulley, and install the crank pulley bolt. ST 499977400 CRANK PULLEY WRENCH (1) Clean the crankshaft thread using compressed air. (2) Apply engine oil to the crank pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (4) Tighten the crank pulley bolts. Tightening torque: 130 Nm (13.3 kgf-m, 95.9 ft-lb)
ST ME-00063
ST ME-00063
3) Check that the tightening angle of the crank pulley bolt is 45 or more. Perform the following procedure when less than 45. CAUTION: If the tightening angle of crank pulley bolt is less than 45, the bolt is damaged. In this case, the bolt must be replaced. (1) Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 (2) Clean the crankshaft thread using compressed air. (3) Apply engine oil to the crank pulley bolt seat and thread. (4) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (5) Tighten the crank pulley bolts by 45 to 60. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover. 4) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
ME(H4DOTC)-44
Crank Pulley
MECHANICAL
2. MT MODEL
1) Install the crank pulley. 2) Use the ST to lock the crank pulley, and install the crank pulley bolt. ST 499977100 CRANK PULLEY WRENCH (1) Clean the crankshaft thread using compressed air. (2) Apply engine oil to the crank pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (4) Tighten the crank pulley bolts. Tightening torque: 180 Nm (18.4 kgf-m, 132.8 ft-lb)
C: INSPECTION
1) Make sure the belt is not worn or otherwise damaged. 2) Check the tension of the belt. <Ref. to ME(H4DOTC)-43, INSPECTION, V-belt.>
ST ME-00063
3) Check that the tightening angle of the crank pulley bolt is 65 or more. Perform the following procedure when less than 65. CAUTION: If the tightening angle of crank pulley bolt is less than 65, the bolt is damaged. In this case, the bolt must be replaced. (1) Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 (2) Clean the crankshaft thread using compressed air. (3) Apply engine oil to the crank pulley bolt seat and thread. (4) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (5) Tighten the crank pulley bolts by 65 to 75. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover. 4) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
ME(H4DOTC)-45
Timing Belt Cover

MECHANICAL
14.Timing Belt Cover

A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the secondary air pump. <Ref. to EC(H4DOTC)-21, REMOVAL, Secondary Air Pump.> 2) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 3) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 4) Remove the timing belt cover LH (A). 5) Remove the timing belt cover RH (B). 6) Remove the front timing belt cover (C).
B: INSTALLATION
1) Install the front timing belt cover (C). Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 2) Install the timing belt cover RH (B). Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 3) Install the timing belt cover LH (A). Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
(B)
(A) (C) ME-00064
(B)
(A) (C) ME-00064
4) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 5) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.> 6) Install the secondary air pump. <Ref. to EC(H4DOTC)-21, INSTALLATION, Secondary Air Pump.>
C: INSPECTION
Check the timing belt cover for damage.
ME(H4DOTC)-46
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. For operation procedures, refer to Timing Belt in the PM section. <Ref. to PM-20, Timing Belt.>
1. TIMING BELT
1) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt guide. (MT model)
ME-00729
5) If the alignment mark or arrow mark (which indicates the direction of rotation) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below. (1) Turn the crankshaft using ST, and align the alignment marks on crank sprocket, intake cam sprocket LH, exhaust cam sprocket LH, intake cam sprocket RH and exhaust cam sprocket RH with marks on oil pump and notches of timing belt cover. ST 499987500 CRANKSHAFT SOCKET
ME-00230
ST ME-00231
ME-03124
ME-00728
ME(H4DOTC)-47
Timing Belt
MECHANICAL
(2) Using white paint, put an alignment mark or an arrow mark on timing belts in relation to the crank sprocket and cam sprockets.

1) Remove the belt idler (A) and (B).
(B) (A)
ME-00070
ME-03936
2) Remove the belt idler No. 2.
ME-03175
Z1: 54.5 teeth Z2: 51 teeth Z3: 28 teeth
ME-00075

Z1 Z2
Z3
Z3
ME-03176
ME-03130
6) Remove the belt idler (A).
(A)
ME-03935
7) Remove the timing belt. CAUTION: After the timing belt has been removed, never rotate the intake and exhaust sprocket. If the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.
ME(H4DOTC)-48
Timing Belt
MECHANICAL
B: INSTALLATION
1) Prepare for installation of the automatic belt tension adjuster assembly. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-in the push adjuster rod gradually taking three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). Push in the adjuster rod to the end face of the cylinder. However, do not press the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. Do not release the press pressure until stopper pin is completely inserted. (1) Attach the automatic belt tension adjuster assembly to vertical pressing tool. (2) Slowly push in the adjuster rod with a pressure of 165 N (16.8 kgf, 37.1 lbf) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder.
2) Install the automatic belt tension adjuster assembly. Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb)
ME-03131
3) Install the belt idler No. 2. Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb)
ME-00075
4) Install the belt idlers. Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb)
ME-00239
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
ME-03449
ME-00350
ME-03567
ME(H4DOTC)-49
Timing Belt
MECHANICAL
2. TIMING BELT
1) Prepare for installation of the automatic belt tension adjuster assembly. <Ref. to ME(H4DOTC)-49, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.> 2) Align the mark (A) on crank sprocket with the mark (B) on oil pump.
5) Align the single line mark (A) on exhaust cam sprocket LH with notch (B) on the timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine).
(B)
(A)
(B)
(A)
ME-00084
ME-03975
3) Align single line mark (A) on the exhaust cam sprocket RH with notch (B) on timing belt cover.
(A)
6) Align the single line mark (A) on intake cam sprocket LH with notch (B) on the timing belt cover by turning the sprocket clockwise (as viewed from front of engine). Make sure the double line marks (C) on the intake and exhaust cam sprockets are aligned.
(B) (A)
(B) (C)
ME-00082
ME-03135
4) Align single line mark (A) on the intake cam sprocket RH with notch (B) on timing belt cover. Make sure that the double line marks (C) on intake and exhaust cam sprockets are aligned.
(B) (A)
(C)
ME-03133
ME(H4DOTC)-50
Timing Belt
MECHANICAL
7) Make sure that the cam and crank sprockets are positioned properly. CAUTION: Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, the valve heads will interfere with each other, resulting in bent valves.
(A)
Do not allow the camshafts to rotate in the direction shown in the upper figure. Doing this may cause both the intake and exhaust valves to lift simultaneously, resulting in mutual interference of heads.
(A)
NG N G OK OK
(A) (A) (B) (A) (B)
ME-03177
(A) Direction of rotation (B) Timing belt installation position

(B) ME-00086
(A) Intake camshaft (B) Exhaust camshaft
When the timing belts are not installed, four camshafts are held at the zero-lift position, where all cams on camshafts are not pushing down on the intake and exhaust valves. (Under this condition, all valves remain unlifted.) When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshaft LH are held, pushing their corresponding valves down. (Under this condition, these valves are held lifted.) Camshaft RH are held so that their cams do not push the valves down. Camshafts LH must be rotated from the zerolift position to the position where the timing belt is to be installed with the smallest possible angle, in order to prevent mutual interference of intake and exhaust valve heads.
ME(H4DOTC)-51
Timing Belt
MECHANICAL
8) Install the timing belt. Align the alignment mark on the timing belt with marks on the sprockets in the alphabetical order shown in the figure. While aligning marks, position the timing belt properly. CAUTION: Disengagement of more than three timing belt teeth may result in interference between the valve and piston. Make sure that the direction of belt rotation is correct.
(1) (2)
(3) (D)
(4)
(5) (B) (A)
(6)
RH-IN
LH-IN
RH-EX
LH-EX
(E)
(7)
(C)
ME-03137
(1) (2) (3)
Arrow mark Timing belt 28-teeth length
(4) (5)
54.5-teeth length 51-teeth length
(6) (7)
28-teeth length Install it in the end
ME(H4DOTC)-52
Timing Belt
MECHANICAL
9) Install the belt idlers. Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb) NOTE: Make sure that the marks on the timing belt and sprockets are aligned.
(2) Check and adjust the clearance between timing belt and timing belt guide using a thickness gauge. Clearance: 1.0r0.5 mm (0.039r0.020 in)
ME-00246 ME-00090
10) After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.
ME-03138
ME-00245
11) Install the timing belt guide. (MT model) (1) Temporarily tighten the bolts mounting the timing belt guide. NOTE: Before installing bolts, clean the bolt holes of timing belt cover. Apply liquid gasket to the threaded portion of cam sprocket. (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent
ME-00731
ME-00732
ME-00230
ME(H4DOTC)-53
Timing Belt
MECHANICAL
(3) Tighten the bolts mounting the timing belt guide. Tightening torque: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
12) Install the timing belt cover. <Ref. to ME(H4DOTC)-46, INSTALLATION, Timing Belt Cover.> 13) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 14) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the timing belt. 2) Check the condition on the back surface of the timing belt. If cracks are found, replace the timing belt. CAUTION: Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. Do not bend the timing belt sharply. In radial diameter h: 60 mm (2.36 in) or more
ME-00247
ME-03124
ME-00248
ME-00728
ME-00729
ME(H4DOTC)-54
Timing Belt
MECHANICAL
2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil on the oil seal of the rod does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 165 N (16.8 kgf, 37.1 lbf) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff and moves freely when applying 165 N (16.8 kgf, 37.1 lbf), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of cylinder. Repeat this operation two to three times. (2) With the adjuster rod moved all the way up, apply a pressure of 165 N (16.8 kgf, 37.1 lbf) to it, and check the adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new part. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-in the push adjuster rod gradually taking three minutes or more. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). Push in the adjuster rod to the end face of the cylinder. However, do not press the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. 4) Measure the amount of rod protrusion H from the end surface of the body. If it is not within specifications, replace the automatic belt tension adjuster assembly with a new part. Amount of rod protrusion H: 5.2 6.2 mm (0.205 0.244 in)
3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly with a new part if faulty. 2) Check the belt tension pulley for smooth rotation. Replace the automatic belt tension adjuster assembly with a new part if abnormal noise or excessive play occurs. 3) Check the belt tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace if noise or excessive play occurs. 2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check the belt idler for grease leakage.
ME-00249
ME(H4DOTC)-55
Cam Sprocket
MECHANICAL
16.Cam Sprocket
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt. <Ref. to ME(H4DOTC)47, REMOVAL, Timing Belt.> 5) Remove the actuator cover of the intake cam sprocket. 6) Fasten the cam sprocket and remove from the cam shaft using ST. ST 499207400 CAM SPROCKET WRENCH
B: INSTALLATION
1) Fasten the cam sprocket and install to the cam shaft using ST. NOTE: Do not confuse the cam sprockets (LH) and (RH) during installation. ST 499207400 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 Nm (3.1 kgf-m, 22.1 ft-lb) of torque, and then tighten further by 45.
ST ME-03282
ST 499977500 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 Nm (3.1 kgf-m, 22.1 ft-lb) of torque, and then tighten further by 45.
ST ME-03282
ST
499977500
CAM SPROCKET WRENCH
ST ME-03283
ST ME-03283
2) Attach the actuator cover of the intake cam sprocket. NOTE: Use new O-rings. Tightening torque: 3.4 Nm (0.3 kgf-m, 2.5 ft-lb) 3) Install the timing belt. <Ref. to ME(H4DOTC)-49, INSTALLATION, Timing Belt.> 4) Install the timing belt cover. <Ref. to ME(H4DOTC)46, INSTALLATION, Timing Belt Cover.> 5) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 6) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the cam sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between cam sprocket and key.
ME(H4DOTC)-56
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt. <Ref. to ME(H4DOTC)47, REMOVAL, Timing Belt.> 5) Remove the crank sprocket.
C: INSPECTION
1) Check the crank sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between crank sprocket and key. 3) Check the crank sprocket protrusion used for sensor for damage and contamination of foreign matter.
ME-00103
B: INSTALLATION
1) Install the crank sprocket.
ME-00103
2) Install the timing belt. <Ref. to ME(H4DOTC)-49, INSTALLATION, Timing Belt.> 3) Install the timing belt cover. <Ref. to ME(H4DOTC)-46, INSTALLATION, Timing Belt Cover.> 4) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 5) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
ME(H4DOTC)-57
Camshaft
MECHANICAL
18.Camshaft
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. Refer to Valve Clearance for preparation procedures. <Ref. to ME(H4DOTC)-26, INSPECTION, Valve Clearance.> 1) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 3) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 4) Remove the timing belt. <Ref. to ME(H4DOTC)47, REMOVAL, Timing Belt.> 5) Remove the cam sprocket. <Ref. to ME(H4DOTC)-56, REMOVAL, Cam Sprocket.> 6) Disconnect the oil flow control solenoid valve assembly connector.
8) Remove the timing belt cover No. 2 RH. NOTE: Do not damage or lose the seal rubber when removing the timing belt covers.
ME-00107
ME-00105
10) Remove the ignition coil. <Ref. to IG(H4DOTC)-7, REMOVAL, Ignition Coil.> 11) Disconnect the PCV hose from the rocker cover.
ME-03094
7) Remove the timing belt cover No. 2 LH.
NOTE: For the PCV hose affixed with the clamp, fit the depression in the ST with the protrusion of the clamp as shown in the figure below, unlock the clamp and disconnect. ST 18353AA000 CLAMP PLIERS
ME-00106
ME-03630
12) Remove the rocker cover and gasket.
ME(H4DOTC)-58
Camshaft
MECHANICAL
13) Remove the union screw without filter (without protrusion) which secures the oil pipe to the front camshaft cap.
(B)
19) Remove the oil seal. CAUTION: Do not scratch the journal surface when removing the oil seal. 20) Similarly, remove the camshaft RH and related parts.
(C)
B: INSTALLATION
1) Install the camshaft. Apply engine oil to the cylinder head at camshaft journal installation location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with base circle of the cam lobe. NOTE: Set the camshaft to the position shown in the figure. When set at the position shown in the figure, it is not necessary to rotate the camshaft RH when installing the timing belt, but it is necessary to rotate the camshaft LH slightly. Intake camshaft LH: Rotate 80 clockwise. Exhaust camshaft LH: Rotate 45 counterclockwise.
A
(a) ME-00771 77.5 (b) 11
(A)
ME-03555
(A) Union screw with filter (with protrusion) (B) Union screw without filter (without protrusion) (C) Oil pipe
14) Loosen the front camshaft cap upper area and intake camshaft cap bolts equally, a little at a time in alphabetical order as shown in the figure.
(A) (E) (C)
(B)
(F)
(D)
15) Loosen the front camshaft cap lower area and exhaust camshaft cap bolts equally, a little at a time in alphabetical order as shown in the figure.
B
(A) (b) (E) (C) 11
77.5 (a)
(B)
(F)
(D) ME-00772
16) Remove the front camshaft cap. 17) Remove the intake camshaft caps and the intake camshaft. 18) Remove the exhaust camshaft caps and the exhaust camshaft. NOTE: Arrange camshaft caps in order so that they can be installed in their original positions.
ME-00111
A B (a) (b)
Cylinder head LH Cylinder head RH Intake camshaft Exhaust camshaft
ME(H4DOTC)-59
Camshaft
MECHANICAL
2) Install the camshaft cap. (1) Apply small amount of liquid gasket to the mating surface of cap. NOTE: Install within 5 minutes after applying liquid gasket. Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to come out and flow toward oil seal, resulting in oil leak. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
3) Apply a coat of engine oil to the camshaft oil seal periphery and oil seal lips, then install the oil seal on the camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499587600 OIL SEAL INSTALLER ST2 499597200 OIL SEAL GUIDE
ST1 ST2 ME-00116
4) Install the oil pipe to the front camshaft cap using the union screw without filter (without protrusion). Tightening torque: 29 Nm (3.0 kgf-m, 21.4 ft-lb)
ME-00773
(2) Apply a thin coat of engine oil to the cap journal surface, and install the camshaft cap to the camshaft. (3) Gradually tighten the camshaft cap in at least two stages in alphabetical order shown in the figure, and then tighten to specified torque. Tightening torque: T1: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb) T2: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(G) T1 T2 (E) (F) T1 (A) (B) T2 (K) (J) (C) (L)
(B)
(C)
(A)
ME-03555
(A) Union screw with filter (with protrusion) (B) Union screw without filter (without protrusion) (C) Oil pipe
5) Similarly, install the parts on right-hand side. 6) Install the tensioner bracket. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
ME-02379
(H)
(D)
(I)
(4) After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at base circle.
ME-00105
ME(H4DOTC)-60
Camshaft
MECHANICAL
7) Install the timing belt cover No. 2 RH. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
12) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. (Outer periphery and ignition coil section) NOTE: Use a new rocker cover gasket. (2) Apply liquid gasket to the specified point of the cylinder head. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
ME-00107
8) Install the timing belt cover No. 2 LH. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
ME-00106
9) Install the cam sprocket. <Ref. to ME(H4DOTC)56, INSTALLATION, Cam Sprocket.> 10) Install the timing belt. <Ref. to ME(H4DOTC)49, INSTALLATION, Timing Belt.> 11) Adjust the valve clearance. <Ref. to ME(H4DOTC)-28, ADJUSTMENT, Valve Clearance.>
ME-03143
(3) Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation. (4) Temporarily tighten the rocker cover tightening bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(C),(K) (H)
(E) (B),(J) (A),(I)
(G) (D),(L) (F) ME-00777
ME(H4DOTC)-61
Camshaft
MECHANICAL
13) Connect the PCV hose to the rocker cover. NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS
C: INSPECTION
1) Measure the bend, and repair or replace if necessary. Service limit: 0.020 mm (0.00079 in) or less
ME-03630
ME-00118
14) Connect the connector to the oil flow control solenoid valve.
2) Check the journal for damage and wear. Replace if faulty. 3) Check the cutout portion used for camshaft sensor for damage. Replace if faulty. 4) Measure the outside diameter of camshaft journal. If the journal diameter is not within the standard, check the oil clearance.
Camshaft journal Front Center, rear 37.946 37.963 29.946 29.963 (1.4939 1.4946) (1.1790 1.1796)
Standard mm (in)
ME-03094
15) Tighten the ignition coil. <Ref. to IG(H4DOTC)7, INSTALLATION, Ignition Coil.> 16) Install the timing belt cover. <Ref. to ME(H4DOTC)-46, INSTALLATION, Timing Belt Cover.> 17) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 18) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
5) Measure the camshaft journal oil clearance. (1) Clean the camshaft cap and cylinder head camshaft journal. (2) Place the camshaft on the cylinder head. (Without installing the valve lifter.) (3) Place a plastigauge across each camshaft journals. (4) Gradually tighten the camshaft cap in at least two stages in alphabetical order shown in the figure, and then tighten to specified torque. Do not turn the camshaft. Tightening torque: T1: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb) T2: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(G) T1 T2 (E) (F) T1 (A) (B) T2 (K) (J) (C) (L)
(H)
(D)
(I)
ME-02379
ME(H4DOTC)-62
Camshaft
MECHANICAL
(5) Remove the camshaft cap. (6) Measure the widest point of the plastigauge on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard: 0.037 0.072 mm (0.0015 0.0028 in)
7) Measure the thrust clearance of camshaft with setting the dial gauge at end of camshaft. If the thrust clearance exceeds the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary replace the camshaft. Standard: 0.068 0.116 mm (0.0027 0.0047 in)
ME-00121 ME-00119
(7) Completely remove the plastigauge. 6) Check the cam face condition; remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the standard or offset wear occurs, replace it. Cam height H: Standard Intake 46.55 46.65 mm (1.833 1.837 in) Exhaust 46.75 46.85 mm (1.841 1.844 in) Cam base circle diameter A: 37.0 mm (1.457 in)
ME-00276
ME(H4DOTC)-63
Cylinder Head
MECHANICAL
19.Cylinder Head
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. Refer to Valve Clearance for preparation procedures. <Ref. to ME(H4DOTC)-26, INSPECTION, Valve Clearance.> When performing the work with the engine installed to body, the following parts must also be removed/installed. Center exhaust pipe <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> Turbocharger <Ref. to IN(H4DOTC)-14, REMOVAL, Turbocharger.> <Ref. to IN(H4DOTC)15, INSTALLATION, Turbocharger.> Joint pipe <Ref. to EX(H4DOTC)-11, REMOVAL, Joint Pipe.> <Ref. to EX(H4DOTC)-11, INSTALLATION, Joint Pipe.> Front exhaust pipe <Ref. to EX(H4DOTC)-5, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-6, INSTALLATION, Front Exhaust Pipe.> 1) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 2) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 3) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 4) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 5) Remove the timing belt. <Ref. to ME(H4DOTC)47, REMOVAL, Timing Belt.> 6) Remove the cam sprocket. <Ref. to ME(H4DOTC)-56, REMOVAL, Cam Sprocket.> 7) Remove the bolt which installs the A/C compressor bracket on cylinder head. 8) Remove the secondary air combination valve. <Ref. to EC(H4DOTC)-22, REMOVAL, Secondary Air Combination Valve.>
9) Remove the oil pipe.

(B) (A) (D) (D) (D)
(C)
(B) (C) (D)
(A) (D) ME-03919
(A) (B) (C) (D)
Union screw with filter (with protrusion) Union screw without filter (without protrusion) Oil pipe Gasket
10) Remove the camshaft. <Ref. to ME(H4DOTC)58, REMOVAL, Camshaft.> 11) Remove the oil level gauge guide. (LH side only) 12) Remove the cylinder head bolts in alphabetical order shown in the figure. NOTE: Leave the bolts (A) and (D) engaged by three or four threads to prevent the cylinder head from falling.
(D) (F) (A)
(B)
(E)
(C) ME-00122
ME(H4DOTC)-64
Cylinder Head
MECHANICAL
13) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (A) and (D) to remove cylinder head.
(D) (F) (A)
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. NOTE: Use a new cylinder head gasket. 2) Tighten the cylinder head bolts. (1) Apply a thin coat of engine oil to washer and bolt thread. (2) Tighten all bolts to 29 Nm (3.0 kgf-m, 21.4 ft-lb) in alphabetical order. (3) Further tighten all bolts to 69 Nm (7.0 kgfm, 50.9 ft-lb) in alphabetical order. (4) Loosen all the bolts by 180 in the reverse order of installing, and loosen them further by 180. (5) Tighten all bolts to 49 Nm (5.0 kgf-m, 36.1 ft-lb) in alphabetical order. (6) Tighten all bolts by 80 to 90 in alphabetical order. (7) Tighten all bolts again by 40 to 45 in alphabetical order. CAUTION: The tightening angle of the bolt should not exceed 45. (8) Further tighten the bolts (A) and (B) by 40 45. CAUTION: Make sure the total re-tightening angle of the step (7) and (8) does not exceed 90.
(C) (A) (F)
(B)
(E)
(C) ME-00122
14) Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. 15) Similarly, remove the right side cylinder head.
(E)
(B)
(D) ME-00123
3) Install the oil level gauge guide. (LH side only) Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 4) Install the camshaft. <Ref. to ME(H4DOTC)-59, INSTALLATION, Camshaft.>
ME(H4DOTC)-65
Cylinder Head
MECHANICAL
5) Install the oil pipe. NOTE: Make sure not to mix up the union screws with filter and without filter as their installation positions are different. Tightening torque: T1: 8 Nm (0.8 kgf-m, 5.9 ft-lb) T2: 29 Nm (3.0 kgf-m, 21.4 ft-lb)
(B) T2 (C) (D) T1 (D) T2 (A) (D) T1
T2 (C)
(B) (D)
(A) (D) ME-03920
T2
(A) (B) (C) (D)
Union screw with filter (with protrusion) Union screw without filter (without protrusion) Oil pipe Gasket
ME-03143
6) Install the secondary air combination valve. <Ref. to EC(H4DOTC)-23, INSTALLATION, Secondary Air Combination Valve.> 7) Install the A/C compressor bracket on cylinder head. Tightening torque: 36 Nm (3.7 kgf-m, 26.6 ft-lb) 8) Install the cam sprocket. <Ref. to ME(H4DOTC)56, INSTALLATION, Cam Sprocket.> 9) Install the timing belt. <Ref. to ME(H4DOTC)-49, INSTALLATION, Timing Belt.> 10) Adjust the valve clearance. <Ref. to ME(H4DOTC)-28, ADJUSTMENT, Valve Clearance.>
(3) Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation.
ME(H4DOTC)-66
Cylinder Head
MECHANICAL
(4) Temporarily tighten the rocker cover tightening bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(C),(K) (H)
C: DISASSEMBLY
1) Remove the valve lifter. 2) Place the cylinder head on ST1. ST1 498267600 CYLINDER HEAD TABLE 3) Using ST2, compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST2 499718000 VALVE SPRING REMOVER NOTE: Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. Keep all the removed parts in order for re-installing in their original positions. For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to Inspection. <Ref. to ME(H4DOTC)-70, VALVE GUIDE, INSPECTION, Cylinder Head.> <Ref. to ME(H4DOTC)-73, INTAKE AND EXHAUST VALVE OIL SEAL, INSPECTION, Cylinder Head.>
(E) (B),(J) (A),(I)
(G) (D),(L) (F) ME-00777
12) Install the timing belt cover. <Ref. to ME(H4DOTC)-46, INSTALLATION, Timing Belt Cover.> 13) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 14) Install the intake manifold. <Ref. to FU(H4DOTC)-20, INSTALLATION, Intake Manifold.> 15) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
ST2
ST1
ME-03142
ME(H4DOTC)-67
Cylinder Head
MECHANICAL
D: ASSEMBLY
(1) (3)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(2)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(12) (4) (10) (6) (12) (4) (10) (6) (7) (8) (9) (7) (8) (9)
ME-03077
(1) (2) (3) (4)
Exhaust valve Intake valve Cylinder head Valve spring seat
(5) (6) (7) (8)
Intake valve oil seal Valve spring Retainer Retainer key
(9) (10) (11) (12)
Valve lifter Exhaust valve oil seal Intake valve guide Exhaust valve guide
ME(H4DOTC)-68
Cylinder Head
MECHANICAL
1) Install the valve spring and valve. (1) Coat the stem of each valve with engine oil and insert the valve into the valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. (2) Set the cylinder head on ST1. ST1 498267600 CYLINDER HEAD TABLE (3) Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its closecoiled end facing the seat on cylinder head. (4) Set the ST2 on valve spring. ST2 499718000 VALVE SPRING REMOVER
E: INSPECTION
1. CYLINDER HEAD
1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Measure the warping of the cylinder head surface that mates with cylinder block using a straight edge (A) and thickness gauge (B). If the warping exceeds the limit, correct the surface by grinding it with a surface grinder. Warping limit: 0.035 mm (0.0014 in) Grinding limit: 0.3 mm (0.012 in)
ST2
Standard height of cylinder head: 127.5 mm (5.02 in) NOTE: Uneven torque for the cylinder head bolts can cause warping. When reinstalling, pay special attention to the torque so as to tighten evenly.
ME-03142 (A)
ST1
(5) Compress the valve spring and fit the valve spring retainer key. (6) After installing, tap the valve spring retainers lightly with a plastic hammer for better seating. 2) Apply oil to the surface of valve lifter. 3) Install the valve lifter.
(B) ME-00126
ME(H4DOTC)-69
Cylinder Head
MECHANICAL
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced. Valve seat width W: Standard Intake 0.6 1.4 mm (0.024 0.055 in) Exhaust 1.2 1.8 mm (0.047 0.071 in)
3. VALVE GUIDE
1) Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge. Clearance between the valve guide and valve stem: Standard Intake 0.030 0.057 mm (0.0012 0.0022 in) Exhaust 0.040 0.067 mm (0.0016 0.0026 in) 2) If the clearance between valve guide and valve stem exceeds the standard, replace the valve guide or valve itself, whichever shows the greater amount of wear or damage. See the following procedure for valve guide replacement. Valve guide inner diameter: 6.000 6.012 mm (0.2362 0.2367 in)
ME-00127
ME-00287
Valve stem outer diameters: Intake 5.955 5.970 mm (0.2344 0.2350 in) Exhaust 5.945 5.960 mm (0.2341 0.2346 in) (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. (2) Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
ST2
ST1 ME-00128
ME(H4DOTC)-70
Cylinder Head
MECHANICAL
(3) Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA020 VALVE GUIDE ADJUSTER
(7) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. NOTE: Apply engine oil to the ST when reaming. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. ST 499767400 VALVE GUIDE REAMER
ST
ME-00757
(4) Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head. (5) Put a new valve guide, coated with sufficient oil, in the cylinder head, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 18251AA020 VALVE GUIDE ADJUSTER
ST1 ST2
ME-00294
(8) After reaming, clean the valve guide to remove chips. (9) Recheck the contact condition between valve and valve seat after replacing the valve guide.
ME-00130
(6) Check the valve guide protrusion. Valve guide protrusion L: 15.8 16.2 mm (0.622 0.638 in)
ME(H4DOTC)-71
Cylinder Head
MECHANICAL

1) Inspect the flange and stem of valve, and replace the valve with a new part if damaged, worn, deformed, or if H exceeds the specified limit. Head edge thickness H: Standard Intake (A) 1.0 1.4 mm (0.039 0.055 in) Exhaust (B) 1.3 1.7 mm (0.051 0.067 in)
5. VALVE SPRING
1) Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table. 2) To measure the squareness of the valve spring, stand the valve spring on a surface plate and measure its deflection at the top of the spring using a try square.
Free length mm (in) 47.32 (1.863) 205 235 (20.9 24.0, Set Tension/spring 46.1 52.8)/36.0 (1.417) height 426 490 (43.4 50.0, N (kgf, lbf)/mm (in) Lift 95.8 110)/26.50 (1.041) Squareness 2.5, 2.1 mm (0.083 in) or less
(A)
(B)
ME-00283
ME-00758
2) Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Replace with a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake 104.4 mm (4.110 in) Exhaust 104.65 mm (4.1201 in)
ME(H4DOTC)-72
Cylinder Head
MECHANICAL

1) For the following, replace the oil seal with a new part. See the procedure 2) and subsequent for replacement procedures. When the lip is damaged. When the spring is out of the specified position. When readjusting the surfaces of valve and valve seat. When replacing the valve guide. 2) Place the cylinder head on ST1, and use ST2 to press-fit the oil seal. ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE NOTE: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer, etc. or strike in. The intake valve oil seals and exhaust valve oil seals are distinguished by their colors. Color of rubber part: Intake [Gray] Exhaust [Green]
ST2
7. VALVE LIFTER
1) Check the valve lifter visually. 2) Measure the outer diameter of valve lifter. Outer diameter: 34.959 34.975 mm (1.3763 1.3770 in)
ME-00134
3) Measure the inner diameter of valve lifter mating surface on cylinder head. Inner diameter: 34.994 35.016 mm (1.3777 1.3786 in)
ME-00135
ME-00133
NOTE: If difference between outer diameter of valve lifter and inner diameter of its mating surface is not within the standard or there is uneven wear, replace the cylinder head. Standard: 0.019 0.057 mm (0.0007 0.0022 in)
ME(H4DOTC)-73
Cylinder Block
MECHANICAL
20.Cylinder Block
A: REMOVAL
NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 2) Remove the intake manifold. <Ref. to FU(H4DOTC)-16, REMOVAL, Intake Manifold.> 3) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 4) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 5) Remove the timing belt. <Ref. to ME(H4DOTC)47, REMOVAL, Timing Belt.> 6) Remove the cam sprocket. <Ref. to ME(H4DOTC)-56, REMOVAL, Cam Sprocket.> 7) Remove the crank sprocket. <Ref. to ME(H4DOTC)-57, REMOVAL, Crank Sprocket.> 8) Remove the generator and A/C compressor with their brackets. 9) Remove the camshaft. <Ref. to ME(H4DOTC)58, REMOVAL, Camshaft.> 10) Remove the cylinder head. <Ref. to ME(H4DOTC)-64, REMOVAL, Cylinder Head.> 11) Remove the clutch disc and cover. (MT model) <Ref. to CL-13, REMOVAL, Clutch Disc and Cover.> 12) Remove the flywheel. (MT model) <Ref. to CL16, REMOVAL, Flywheel.> 13) Use the ST to lock the crankshaft, and remove the drive plate. (AT model) ST 498497100 CRANKSHAFT STOPPER
19) Remove the bolts which install oil pump onto cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
LU-00015
20) Remove the oil pump from cylinder block using a flat tip screwdriver. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
ME-00138
21) Remove the front oil seal from the oil pump. 22) Remove the oil pan. (1) Set the part so that the cylinder block LH is on the upper side. (2) Remove the bolts which secure oil pan to cylinder block. (3) Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter. 23) Remove the oil strainer. 24) Remove the baffle plate. 25) Remove the water tank pipe assembly.
ST ME-00136
14) Remove the oil separator cover. 15) Remove the water by-pass pipe for heater. 16) Remove the oil filter. <Ref. to LU(H4SO)-23, REMOVAL, Engine Oil Filter.> 17) Remove the oil cooler. <Ref. to LU(H4SO)-22, REMOVAL, Engine Oil Cooler.> 18) Remove the water pump. <Ref. to CO(H4DOTC)-16, REMOVAL, Water Pump.>
ME(H4DOTC)-74
Cylinder Block
MECHANICAL
26) Remove the water pipe assembly.
ME-00300
(2) (3) (4)
(1)
(6) (4)
(3)
(5)
(4) (2) (1) (3)
(8) (4) (3) (1) (2) ME-02889 (7)
(1) (2) (3)
Service hole plug Gasket Snap ring
(4) (5) (6)
Piston pin Service hole cover O-ring
(7) (8)
Seal washer Washer
ME(H4DOTC)-75
Cylinder Block
MECHANICAL
27) Remove the service hole plugs using a hexagon wrench [14 mm].
ME-00140
28) Remove the service hole cover. 29) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
ME-00141
30) Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
ST
ME-03325
31) Similarly draw out the piston pins from #3 and #4 pistons. 32) Remove the cylinder block connecting bolt on the RH side. 33) Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns. 34) Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
ME(H4DOTC)-76
Cylinder Block
MECHANICAL
35) Separate the cylinder block LH and RH. NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
(5) (7) (1) (4)
(2) (6) (4)
(3)
(1)
(5) ME-02890
(1) (2) (3)
Cylinder block Rear oil seal Crankshaft
(4) (5)
Crankshaft bearing Piston
(6) (7)
Seal washer Washer
36) Remove the rear oil seal. 37) Remove the crankshaft together with connecting rod. 38) Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Press the crankshaft bearing at the end opposite to locking lip to remove. Be careful not to confuse the crankshaft bearing combination. 39) Draw out each piston from cylinder block using wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.
ME(H4DOTC)-77
Cylinder Block
MECHANICAL
B: INSTALLATION
(6)
(5)
(4)
(7)
(1)
(3)
(7) (6) (7) (6)
(3)
(2)
ME-03186
(1) (2) (3)
Crankshaft bearing Crankshaft Cylinder block
(4) (5)
Rear oil seal O-ring
(6) (7)
Seal washer Washer
1) Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal. 2) Position the crankshaft and O-ring on the cylinder block RH. NOTE: Use new O-rings. 3) Apply liquid gasket to the mating surfaces of cylinder block RH, and position the cylinder block LH. NOTE: Install within 5 minutes after applying liquid gasket. Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
ME-00145
ME(H4DOTC)-78
Cylinder Block
MECHANICAL
4) Apply a coat of engine oil to the washer and bolt thread. NOTE: Use new seal washer. 5) Tighten the 10 mm cylinder block connecting bolts on the LH side (A D) in alphabetical order. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
8) Tighten the RH side cylinder block connecting bolts (E J) further in alphabetical order. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(E) (G)
(J)
(A) (D) (I) (H) (F) ME-00780 (B) (C) ME-00779
9) Tighten the LH side cylinder block connecting bolts (A D) further in alphabetical order. (A), (C): Angle tightening Tightening angle: 90 (B), (D): Torque tightening Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
6) Tighten the 10 mm cylinder block connecting bolts on the RH side (E J) in alphabetical order. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
(E) (G)
(J) (D)
(A)
(B) (I) (H) (F) ME-00780 (C) ME-00779
7) Tighten the LH side cylinder block connecting bolts (A D) further in alphabetical order. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
10) Tighten the RH side cylinder block connecting bolts (E J) further in alphabetical order. Tightening angle: 90
(A) (D) (G)
(E)
(J)
(B) (C) ME-00779 (I) (H) (F) ME-00780
ME(H4DOTC)-79
Cylinder Block
MECHANICAL
11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A H) in alphabetical order. Tightening torque: (A) (G): 25 Nm (2.5 kgf-m, 18.4 ft-lb) (H): 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(G)
15) Position the upper rail gap at (C) in the figure.
25 (E) (C) (A) (B)
(C)
ME-02087
16) Align the upper rail spin stopper (E) to the side hole (D) on the piston.
(D) (D) (H) (F) ME-00147 (E)
(B) ST2 (A) (F)
ME-02471
17) Position the expander gap at (F) in the figure on the 180 opposite direction of (C).
ST1 ME-00148 ME-02088
(A) Rear oil seal (B) Flywheel attaching bolt
18) Set the lower rail gap at position (G), located 120 clockwise from (C) in the figure.
13) Position the top ring gap at (A) or (B) in the figure. 14) Position the second ring gap at 180 on the reverse side the top ring gap.
(G)
(C)
(A)
(B)
120
ME-02089
ME-00718
NOTE: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area.
ME(H4DOTC)-80
Cylinder Block
MECHANICAL
19) Install the snap ring. Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side. NOTE: Use new snap rings.
#3
#1
#4
(A)
#2
ME-00306
(A) Front side

(5) (4) (1) (3) (2) T (5) (4) (3) (2)
(1)
ME-02442
(1) (2) (3)
Piston Piston pin Snap ring
(4) (5)
Gasket Service hole plug
ME(H4DOTC)-81
Cylinder Block
MECHANICAL
20) Install the piston. (1) Set the parts so that the #1 and #2 cylinders are on the upper side. (2) Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE
ST1
(3) Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. (4) Install the snap ring. NOTE: Use new snap rings.
ME-00159
(5) Apply liquid gasket to the threaded portion of the service hole plug.
ST2 ME-00157
NOTE: Face the piston front mark towards the front of the engine.
Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent
(A)
ME-00160
ME-00742
(A) Front mark
21) Install the piston pin. (1) Apply a coat of engine oil to ST3. (2) Insert ST3 into the service hole to align the piston pin hole and the connecting rod small end. ST3 499017100 PISTON PIN GUIDE
ST1
ST3
ME-00158
ME(H4DOTC)-82
Cylinder Block
MECHANICAL
(6) Install the service hole plug and gasket. NOTE: Use a new gasket. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
ME-00140 (5)
T2 (4)
T1 (6)
(3) (2) (1)
(7) (3) (2)
(1) ME-02440
(1) (2) (3) (4)
Piston Piston pin Snap ring Gasket
(5) (6) (7)
Service hole plug Service hole cover O-ring
ME(H4DOTC)-83
Cylinder Block
MECHANICAL
(7) Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins. (8) Install the service hole cover. NOTE: Use new O-rings. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 22) Install the water pipe assembly. NOTE: Use new O-rings. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
27) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
(A) LU-02353
(A) Gasket
ME-00300
23) Install the water tank pipe assembly. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 24) Install the baffle plate. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 25) Install the oil strainer. NOTE: Use new O-rings. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb) 26) Tighten the oil strainer stay together with the baffle plate. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
28) Apply liquid gasket to the mating surfaces of the oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover. NOTE: Install within 5 minutes after applying liquid gasket. Use new oil separator cover. Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent Bolt thread (A) (when reusing the bolt) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(A)
ME-03333
ME(H4DOTC)-84
Cylinder Block
MECHANICAL
29) Use the ST to lock the crankshaft, and install the drive plate. (AT model) ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 Nm (7.3 kgf-m, 53.1 ft-lb)
(3) Apply a coat of engine oil to the inside of oil seal.
ME-00312
ST ME-00136
(4) Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation. NOTE: Make sure the oil seal lip is not folded. Align the flat surface of oil pumps inner rotor with crankshaft before installation. Use new O-rings and oil seals. Do not forget to assemble O-rings. (5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
30) Install the flywheel. (MT model) <Ref. to CL-16, INSTALLATION, Flywheel.> 31) Install the clutch disc and cover. (MT model) <Ref. to CL-13, INSTALLATION, Clutch Disc and Cover.> 32) Install the oil pump. (1) Install the front oil seal using the ST. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal.
ST
LU-00021
(2) Apply liquid gasket to the matching surface of oil pump. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent
T LU-02103
(A)
ME-00165
(A) O-ring
ME(H4DOTC)-85
Cylinder Block
MECHANICAL
33) Install the water pump and gasket. NOTE: When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Use a new gasket. Tightening torque: First: 12 Nm (1.2 kgf-m, 8.9 ft-lb) Second: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
(B) (C) (A) (D)
(E)
(F)
ME-02463
34) Install the water by-pass pipe for heater. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 35) Install the oil cooler. <Ref. to LU(H4SO)-22, INSTALLATION, Engine Oil Cooler.> 36) Install the oil filter. <Ref. to LU(H4SO)-23, INSTALLATION, Engine Oil Filter.> 37) Install the cylinder head. <Ref. to ME(H4DOTC)-65, INSTALLATION, Cylinder Head.> 38) Install the camshaft. <Ref. to ME(H4DOTC)59, INSTALLATION, Camshaft.> 39) Install the generator and A/C compressor with their brackets. Tightening torque: 36 Nm (3.7 kgf-m, 26.6 ft-lb) 40) Install the crank sprocket. <Ref. to ME(H4DOTC)-57, INSTALLATION, Crank Sprocket.> 41) Install the cam sprocket. <Ref. to ME(H4DOTC)-56, INSTALLATION, Cam Sprocket.> 42) Install the timing belt. <Ref. to ME(H4DOTC)49, INSTALLATION, Timing Belt.> 43) Adjust the valve clearance. <Ref. to ME(H4DOTC)-28, ADJUSTMENT, Valve Clearance.>
ME-03143
(3) Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation. (4) Temporarily tighten the rocker cover tightening bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(C),(K) (H)
(E) (B),(J) (A),(I)
(G) (D),(L) (F) ME-00777
ME(H4DOTC)-86
Cylinder Block
MECHANICAL
45) Install the timing belt cover. <Ref. to ME(H4DOTC)-46, INSTALLATION, Timing Belt Cover.> 46) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 47) Install the intake manifold. <Ref. to FU(H4DOTC)-20, INSTALLATION, Intake Manifold.> 48) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>
C: DISASSEMBLY
(1) (2)
(2)
(7)
(5) (4) (3) (6)
ME-03556
(1) (2) (3)
(4) (5)
(6) (7)
1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Keep the removed connecting rods, connecting rod caps and bearings in order so that they are kept in their original combinations/groups, and not mixed together. 3) Remove the piston rings using piston ring expander. 4) Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order, to prevent confusion. 5) Remove the snap ring.
ME(H4DOTC)-87
Cylinder Block
MECHANICAL
D: ASSEMBLY
T (3) (1)
(1) (2)
(4) (5) (8) (7) (6)
ME-02985
(1) (2) (3) (4)
Connecting rod bearing Connecting rod Connecting rod cap Oil ring
(5) (6) (7) (8)
Second ring Top ring Snap ring Side mark
1) Apply oil to the surface of the connecting rod bearings, and install the connecting rod bearings on connecting rods and connecting rod caps. 2) Position each connecting rod with a side mark facing forward, and install it. 3) Attach the connecting rod cap, and tighten with the connecting rod bolt. Make sure the arrow mark on connecting rod cap facing front during installation. NOTE: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads. Tightening torque: 52 Nm (5.3 kgf-m, 38.4 ft-lb) 4) Install the oil ring upper rail, expander and lower rail by hand. 5) Install the second ring and top ring using piston ring expander. NOTE: Assemble so that the piston ring mark R faces the top side of the piston.
ME(H4DOTC)-88
Cylinder Block
MECHANICAL
E: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Check the oil passages for clogging. 3) Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.025 mm (0.00098 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

(A)
(B)
#5 #4 #3 #2 #1
(E) (C) ME-00170
(A) (B) (C) (D) (E) (F)
Main journal size mark Cylinder block (RH) (LH) combination mark #1 cylinder bore size mark #2 cylinder bore size mark #3 cylinder bore size mark #4 cylinder bore size mark
ME(H4DOTC)-89
4 5 B A
(F) (D)
Cylinder Block
MECHANICAL
2) Measure inner diameter of each cylinder. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20C (68F). Taper: Standard 0.015 mm (0.0006 in) Out-of-roundness: Standard 0.010 mm (0.0004 in)
(A) (B)
4) Measure outer diameter of each cylinder. Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20C (68F). Piston grade point H: 38.2 mm (1.50 in) Piston outer diameter: Standard A: 99.505 99.515 mm (3.9175 3.9179 in) B: 99.495 99.505 mm (3.9171 3.9175 in) 0.25 mm (0.0098 in) oversize 99.745 99.765 mm (3.9270 3.9278 in) 0.50 mm (0.0197 in) oversize 99.995 100.015 mm (3.9368 3.9376 in)
H H1 H2 H3 H4 ME-00172
5) Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20C (68F).
ME-00171
(A) (B) H1: H2: H3: H4:
Piston pin direction Thrust direction 10 mm (0.39 in) 45 mm (1.77 in) 80 mm (3.15 in) 115 mm (4.53 in)
Cylinder to piston clearance at 20C (68F): Standard 0.010 0.010 mm (0.00039 0.00039 in) 6) Boring and honing (1) If any of the measured value of taper, out-ofroundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replaced with oversize pistons. (2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature. Cylinder inner diameter boring limit (diameter): 100.005 mm (3.9372 in)
3) When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance.
ME(H4DOTC)-90
Cylinder Block
MECHANICAL

1) Check the piston and piston pin for breaks, cracks or wear. Replace if faulty. 2) Check the piston ring groove for wear and damage. Replace if faulty. 3) Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20C (68F). Replace if faulty. Standard clearance between piston pin and hole in piston: Standard 0.004 0.008 mm (0.0002 0.0003 in)
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: The top ring and second ring have the mark to determine the direction for installing. When installing the ring to piston, face this mark to the top side. Oil ring consists of the upper rail, expander and lower rail. When installing oil ring on piston, be careful of the direction of each rail.
(A) (B) (C)
ME-00173 (A)
(B)
(C)
ME-00174
ME-02480
(A) Upper rail (B) Expander (C) Lower rail
(A)
ME-00175
ME(H4DOTC)-91
Cylinder Block
MECHANICAL
2) Using the piston, insert the piston ring and oil ring into the cylinder so that they are perpendicular to the cylinder wall, and measure the piston ring gap with a thickness gauge.
Standard mm (in) 0.20 0.25 (0.0079 0.0098) 0.37 0.52 (0.015 0.020) 0.20 0.50 (0.0079 0.0197)
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)
(A)
Top ring Piston ring gap Second ring Oil ring rail
(B)
ME-00177
Standard mm (in) 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028)
(A)
(B)
ME-00179
3) Install the connecting rod fitted with bearing to the crankshaft, and measure the thrust clearance using a thickness gauge. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod. Connecting rod thrust clearance: Standard 0.070 0.330 mm (0.0028 0.0130 in)
ME-00178
ME-00180
ME(H4DOTC)-92
Cylinder Block
MECHANICAL
5) Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. Connecting rod oil clearance: Standard 0.017 0.045 mm (0.0007 0.0018 in)
Bearing Standard 0.03 (0.0012) undersize 0.05 (0.0020) undersize 0.25 (0.0098) undersize Bearing size (Thickness at center) 1.490 1.502 (0.0587 0.0591) 1.504 1.512 (0.0592 0.0595) 1.514 1.522 (0.0596 0.0599) 1.614 1.622 (0.0635 0.0639) Unit: mm (in) Outer diameter of crank pin 51.984 52.000 (2.0466 2.0472) 51.954 51.970 (2.0454 2.0461) 51.934 51.950 (2.0447 2.0453) 51.734 51.750 (2.0368 2.0374)
8) The replacement procedure for the connecting rod small end bushing is as follows. (1) Remove the bushing from connecting rod with ST and press. (2) Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER
ST
ME-00182
6) Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged. 7) Measure the piston pin clearance at connecting rod small end. If the measured value is not within the standard, replace it with a new part. Clearance between piston pin and bushing: Standard 0 0.022 mm (0 0.0009 in)
(3) Make two 3 mm (0.12 in) holes in the pressed bushing by aligning with the pre-manufactured holes on the connecting rod, and ream the inside of the bushing. (4) After completion of reaming, clean the bushing to remove chips.

1) Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft. 2) Measure warping of the crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
ME-00181
ME-00183 ME-00174
ME(H4DOTC)-93
Cylinder Block
MECHANICAL
3) Inspect the crank journal and crank pin for wear. If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in) Grinding limit (dia.) To 51.750 mm (2.0374 in) Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 59.758 mm (2.3527 in)
ME-00184
Unit: mm (in) Crank journal diameter #1, #3 #2, #4, #5 59.992 60.008 59.992 60.008 (2.3619 2.3625) (2.3619 2.3625) 1.998 2.011 2.000 2.013 (0.0787 0.0792) (0.0787 0.0793) 59.962 59.978 (2.3607 2.3613) 2.017 2.020 (0.0794 0.0795) 59.942 59.958 (2.3599 2.3605) 2.027 2.030 (0.0798 0.0799) 59.742 59.758 (2.3520 2.3527) 2.127 2.130 (0.0837 0.0839) 59.962 59.978 (2.3607 2.3613) 2.019 2.022 (0.0795 0.0796) 59.942 59.958 (2.3599 2.3605) 2.029 2.032 (0.0799 0.0800) 59.742 59.758 (2.3520 2.3527) 2.129 2.132 (0.0838 0.0839) Crank pin outer diameter 51.984 52.000 (2.0466 2.0472) 1.490 1.502 (0.0587 0.0591) 51.954 51.970 (2.0454 2.0461) 1.504 1.512 (0.0592 0.0595) 51.934 51.950 (2.0447 2.0453) 1.514 1.522 (0.0596 0.0599) 51.734 51.750 (2.0368 2.0374) 1.614 1.622 (0.0635 0.0639)
0.03 (0.0012) Undersize
0.05 (0.0020) Undersize
0.25 (0.0098) Undersize
ME(H4DOTC)-94
Cylinder Block
MECHANICAL
4) Use a thickness gauge to measure the thrust clearance of crankshaft at #5 crank journal bearing. If clearance exceeds the standard, replace the bearing. Crankshaft thrust clearance: Standard 0.030 0.115 mm (0.0012 0.0045 in)
ME-00322
5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear. 6) Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 0.030 mm (0.0004 0.0012 in)
ME(H4DOTC)-95

MECHANICAL

A: SPECIFICATION
Refer to Cylinder Head for removal and installation procedures of the intake and exhaust valves. <Ref. to ME(H4DOTC)-64, REMOVAL, Cylinder Head.> <Ref. to ME(H4DOTC)-65, INSTALLATION, Cylinder Head.>
ME(H4DOTC)-96
Piston
MECHANICAL
22.Piston
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of pistons. <Ref. to ME(H4DOTC)74, REMOVAL, Cylinder Block.> <Ref. to ME(H4DOTC)-78, INSTALLATION, Cylinder Block.>
ME(H4DOTC)-97
Connecting Rod
MECHANICAL
23.Connecting Rod
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of connecting rods. <Ref. to ME(H4DOTC)-74, REMOVAL, Cylinder Block.> <Ref. to ME(H4DOTC)-78, INSTALLATION, Cylinder Block.>
ME(H4DOTC)-98
Crankshaft
MECHANICAL
24.Crankshaft
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of the crankshaft. <Ref. to ME(H4DOTC)-74, REMOVAL, Cylinder Block.> <Ref. to ME(H4DOTC)-78, INSTALLATION, Cylinder Block.>
ME(H4DOTC)-99

MECHANICAL

A: INSPECTION
Symptoms 1. Engine does not start. 1) Starter does not turn. Problem parts etc. Starter Possible cause RANK B C C B A A B C C C C A A C B B B C C C C C B C B B
Defective battery-to-starter harness Defective starter switch Defective inhibitor switch Defective starter Battery Improper connection of the terminal Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Starter Defective starter Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)
ME(H4DOTC)-100

MECHANICAL
Symptoms 3) Initial combustion occurs. Problem parts etc. Possible cause Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) RANK A B B C C B B B C C C C C B C B B A B C C B B C C B B B C C C C C B C B B
ME(H4DOTC)-101

MECHANICAL
Symptoms 2. Rough idle and engine stall Problem parts etc. Possible cause Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Over-heating Others Evaporative emission control system malfunction Stuck or damaged throttle valve RANK A A A A B B C B C C C B C B B B B C B B A B B C C A B
ME(H4DOTC)-102

MECHANICAL
Symptoms 3. Low output, hesitation and poor acceleration Problem parts etc. Possible cause Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Cooling system Over-heating Over-cooling Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Cooling system Over-heating Others Evaporative emission control system malfunction RANK A A A B B B B B A B B C B B B B B C B C A B B C C A A A A A B B B B B B B C B B C C C C C C A B B C
4. Surging
ME(H4DOTC)-103

MECHANICAL
Symptoms 5. Engine does not return to idle. 6. Dieseling (Run-on) Problem parts etc. Possible cause RANK A A A A B B A C C B B C B B C C B C C C A C C C A B B C B A A B C A A B B B B B B
7. After burning in exhaust system
8. Knocking
Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Over-heating Intake system Loosened or cracked PCV hose Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter gasket Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan
ME(H4DOTC)-104

MECHANICAL
Symptoms Problem parts etc. Possible cause 10. Excessive fuel consump- Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> tion Intake system Dirty air cleaner element Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling RANK A A B B C C B C C B B C C
ME(H4DOTC)-105
Engine Noise
MECHANICAL
26.Engine Noise
A: INSPECTION
Type of sound Condition Sound increases as engine speed increases. Regular clicking sound Oil pressure is low. Heavy and dull clank Oil pressure is normal. Sound is noticeable when High-pitched clank accelerating with an overload condition. Noise is reduced when fuel Clank when engine speed is injector connector of noisy cyl- between 1,000 and 2,000 rpm. inder is disconnected. (NOTE*) Noise is reduced when fuel injector connector of noisy cylinder is disconnected. (NOTE*) Sound is not reduced if each fuel injector connector is disconnected in turn. (NOTE*) Possible cause Valve mechanism is defective. Incorrect valve clearance Worn camshaft Broken valve spring Worn crankshaft main bearing Worn connecting rod bearing (large end) Loosened flywheel mounting bolt Damaged engine mounting Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong heat range of spark plug Improper octane value of gasoline Worn crankshaft main bearing Worn connecting rod bearing (large end)
Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Unusually worn valve lifter Worn cam sprocket Worn camshaft journal bore in cylinder head Insufficient generator lubrication Poor contact of generator brush and rotor Defective ignition starter switch Worn gear and starter pinion Loose V-belt Defective water pump shaft Insufficient compression Air leakage in air intake system, hose, connection or manifold Loose timing belt Timing belt contacting with adjacent part Incorrect valve clearance
Squeaky sound Rubbing sound Gear scream when starting engine Sound like polishing glass with a dry cloth Hissing sound Timing belt noise Valve noise
NOTE*) When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H4DOTC)-106
General Description
EXHAUST
A: COMPONENT
1. FRONT EXHAUST PIPE
(16) T1 T4
T4 T4
(1) T1 (2) T4 (17) (3) (5) A T3 (6) (4) (8) (19) (11) (7) T1 (13) (6) (18) (9) T4 (1) (12) (14) (15) A
T5
(9) (10) T3 T1
T2
T2 T2
T2 EX-02330
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Gasket Exhaust manifold RH upper cover Exhaust manifold RH Exhaust manifold RH lower cover Front exhaust pipe upper cover Front exhaust pipe insulator RH Gasket Front exhaust pipe Front exhaust pipe insulator LH Front exhaust pipe lower cover
(11) (12) (13) (14) (15) (16) (17) (18) (19)
Gasket Exhaust manifold LH inner cover Exhaust manifold LH outer cover Gasket Turbocharger joint pipe Gasket Front oxygen (A/F) sensor Exhaust manifold LH Ground cable
Tightening torque:Nm (kgf-m, ft-lb) T1: 19 (1.9, 14.0) T2: 25 (2.5, 18.4) T3: 40 (4.1, 29.5) T4: 42.5 (4.3, 31.3) T5: <Ref. to FU(H4DOTC)-46, INSTALLATION, Front Oxygen (A/F) Sensor.>
EX(H4DOTC)-2
General Description
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER

(14) T1 (24) T1 (14) (17) (18) T9 T9 (14) (16) (12) T9 (18) T1 (15) (14) (17) (20) (18) (14) (19) (24) T1
T9 (11) (13) (9) T2 A T8 (1) T8 (3) (10) T8 T5 (2) T6 (23) T7 (22) T4 (5) (7) (8) T3 (4) (6) T3 T10 T2 A
(18)
(21) EX-02369
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Gasket Front catalytic converter Center exhaust pipe (Front) Center exhaust pipe (Rear) Gasket Center pipe upper cover (Rear) Clamp Rear catalytic converter lower cover Rear oxygen sensor Rear catalytic converter Gasket Rear exhaust pipe
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Chamber Cushion rubber Spring Bolt Gasket Self-locking nut Muffler LH Muffler RH Hanger bracket (AT model) Hanger bracket (5MT model) Hanger bracket (6MT model) Muffler cutter
Tightening torque:Nm (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: 13 (1.3, 9.6) T3: 18 (1.8, 13.3) T4: 23 (2.3, 17.0) T5: 30 (3.1, 22.1) T6: 35 (3.6, 25.8) T7: 40 (4.1, 29.5) T8: 42.5 (4.3, 31.3) T9: 48 (4.9, 35.4) T10: <Ref. to FU(H4DOTC)-48, INSTALLATION, Rear Oxygen Sensor.>
EX(H4DOTC)-3
General Description
EXHAUST
B: CAUTION
EX(H4DOTC)-4
Front Exhaust Pipe

EXHAUST

A: REMOVAL
8) While holding the front exhaust pipe assembly with one hand, remove the nuts which hold the front exhaust pipe assembly to cylinder head exhaust port.
EX-02254
IN-00203
3) Lift up the vehicle. 4) Remove the under cover. 5) Remove the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, REMOVAL, Front Oxygen (A/F) Sensor.> 6) Remove the exhaust manifold RH lower cover and exhaust manifold LH cover.
EX-00005
9) Remove the front exhaust pipe assembly. 10) Remove the exhaust manifold RH upper cover and the front exhaust pipe cover. 11) Separate the front exhaust pipe from exhaust manifolds.
EX-02336
7) Remove the bolts and nuts which hold front exhaust pipe assembly onto turbocharger joint pipe.
EX-02328
EX-00018
EX(H4DOTC)-5
Front Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Install the front exhaust pipe and the exhaust manifold. NOTE: Use a new gasket. Tightening torque: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
5) Connect the exhaust manifold RH to the turbocharger joint pipe. NOTE: Use a new gasket. Tightening torque: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
EX-00018 EX-02328
2) Install the front exhaust pipe cover. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 3) Install the exhaust manifold RH upper cover. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb) 4) Install the front exhaust pipe assembly. NOTE: Use a new gasket. Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
6) Install the exhaust manifold RH lower cover and exhaust manifold LH cover. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
EX-02336
7) Install the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, INSTALLATION, Front Oxygen (A/F) Sensor.> 8) Install the under cover. 9) Lower the vehicle. 10) Connect the ground cable to battery.
EX-02254
IN-00203
C: INSPECTION
EX-00005
EX(H4DOTC)-6
Center Exhaust Pipe

EXHAUST
3. Center Exhaust Pipe

A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
9) Remove the bolts which secure the upper side of the turbocharger lower cover.
EX-02337
10) Remove the upper side bolts and nuts that hold the center exhaust pipe on the turbocharger, and remove the turbocharger cover stay (A).
IN-00203
4) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 5) Lift up the vehicle. 6) Remove the bolts which hold the lower side of the turbocharger lower cover.
(A)
EX-02367
11) Lift up the vehicle. 12) Remove the lower side nuts (two places) that hold the center exhaust pipe on the turbocharger.
EX-02366
7) Lower the vehicle. 8) Remove the turbocharger upper cover.

EX-02339
13) Remove clip (A) holding the rear oxygen sensor harness. (AT model)
EX-02256
EX(H4DOTC)-7
Center Exhaust Pipe

EXHAUST
14) Disconnect the connector from rear oxygen sensor. AT model
17) Remove the bolt which holds center exhaust pipe to hanger bracket, and remove the center exhaust pipe. CAUTION: Be careful not to drop the center exhaust pipe.
(A) EX-02368
MT model
EX-00209
18) Remove the turbocharger lower cover. 19) Separate the center exhaust pipe (front) and center exhaust pipe (rear).
EX-02361
15) Separate the center exhaust pipe from rear exhaust pipe.
EX-02259
EX-02015
16) Remove the bolt which holds center exhaust pipe bracket to transmission.
EX-02182
EX(H4DOTC)-8
Center Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Assemble the center exhaust pipe (front) and center exhaust pipe (rear). NOTE: Use a new gasket. Tightening torque: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
6) Install the center exhaust pipe to rear exhaust pipe. NOTE: Use a new gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-02015 EX-02259
2) Set the turbocharger lower cover and temporarily tighten the bolts which hold the lower side of the turbocharger lower cover. 3) Install the center exhaust pipe and temporarily tighten the bolt which holds center exhaust pipe to hanger bracket. 4) Temporarily tighten the bolt which holds the center exhaust pipe to the transmission. 5) Connect the center exhaust pipe along with turbocharger cover stay (A) to the turbocharger. NOTE: Use a new gasket. Tightening torque: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
7) Affix the rear oxygen sensor with the clip (A). (AT model) 8) Connect the rear oxygen sensor connector. AT model
(A) EX-02368
MT model
EX-02339
EX-02361
(A)
EX-02367
EX(H4DOTC)-9
Center Exhaust Pipe

EXHAUST
9) Tighten the bolt which holds center exhaust pipe bracket to transmission. Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft-lb)
13) Install the turbocharger upper cover. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
EX-02256 EX-02182
10) Tighten the bolt which holds center exhaust pipe to hanger bracket. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
14) Lift up the vehicle. 15) Tighten the bolts which hold the lower side of the turbocharger lower cover. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
EX-00209
EX-02366
11) Lower the vehicle. 12) Attach the bolt which holds the upper side of the turbocharger lower cover. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
16) Lower the vehicle. 17) Install the intercooler. <Ref. to IN(H4DOTC)13, INSTALLATION, Intercooler.> 18) Connect the ground cable to battery.
IN-00203 EX-02337
C: INSPECTION
EX(H4DOTC)-10
Joint Pipe
EXHAUST
4. Joint Pipe
A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 42.5 Nm (4.3 kgf-m, 31.3 ft-lb)
EX-00018
IN-00203
4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, REMOVAL, Front Oxygen (A/F) Sensor.> 7) Remove the exhaust manifold RH lower cover.
EX-02340
C: INSPECTION
EX-02340
8) Remove the bolts and nuts which hold the front exhaust manifold to joint pipe.
EX-00018
9) Remove the center exhaust pipe. <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 10) Remove the turbocharger. <Ref. to IN(H4DOTC)-14, REMOVAL, Turbocharger.> 11) Take off the joint pipe in the upward direction.
EX(H4DOTC)-11
Rear Exhaust Pipe

EXHAUST

A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Separate the rear exhaust pipe from center exhaust pipe.
EX-00219
EX-02015
EX-00222
RH side
EX-00218
EX(H4DOTC)-12
Rear Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Apply a coat of spray type lubricant to the mating area of cushion rubber. 2) Install the rear exhaust pipe bracket to cushion rubber. NOTE: After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.
4) Install the rear exhaust pipe to center exhaust pipe. NOTE: Use a new gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-02015

EX-00219
C: INSPECTION
3) Install the rear exhaust pipe to muffler. NOTE: Use a new gasket and self-locking nut. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb) LH side
EX-00222
RH side
EX-00218
EX(H4DOTC)-13
Muffler
EXHAUST
6. Muffler
A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Separate the muffler from rear exhaust pipe. LH side
RH side
EX-00221
B: INSTALLATION
EX-00222
RH side
EX-00218
EX-00222
4) Apply a coat of spray type lubricant to the mating area of cushion rubber. 5) Remove the cushion rubber, and remove the muffler. CAUTION: Be careful not to drop the muffler during removal. LH side
RH side
EX-00218
C: INSPECTION
EX-00220
EX(H4DOTC)-14
General Description
COOLING
A: SPECIFICATION
Cooling system Total engine coolant capacity Type Discharge rate 2 (US gal, Imp gal) /min. Pump speed Discharge pressure Engine coolant temperature Discharge rate 2 (US gal, Imp gal) /min. Discharge Pump speed Discharge pressure performance II Engine coolant temperature Discharge rate 2 (US gal, Imp gal) /min. Discharge Pump speed Discharge pressure performance III Engine coolant temperature Impeller diameter mm (in) Number of impeller vanes Pump pulley diameter mm (in) Clearance between impeller Standard mm (in) and case Type Starting temperature to open Fully opens Valve lift mm (in) Valve bore mm (in) Main fan W Motor input Sub fan W Main fan Fan diameter / Blade Sub fan Type Discharge performance I Core dimensions Width Height Thickness mm (in) 2 (US qt, Imp qt) Electric fan + Forced engine coolant circulation system AT: approx. 7.2 (7.6, 6.3) MT: approx. 7.3 (7.7, 6.4) Centrifugal impeller type 20 (5.3, 4.4) 760 rpm 2.9 kPa (0.3 mAq) 80C (176F) 100 (26.4, 22.0) 3,000 rpm 49.0 kPa (5.0 mAq) 80C (176F) 200 (52.8, 44.0) 6,000 rpm 225.4 kPa (23.0 mAq) 80C (176F) 76 (2.99) 8 60 (2.36) 0.5 1.5 (0.020 0.059) Wax pellet type 76 80C (169 176F) 91C (196F) 9.0 (0.354) or more 35 (1.38) 120 120 320 mm (12.6 in)/5 320 mm (12.6 in)/7 Down flow 687.4 340 16 (27.06 13.39 0.63) Above: 108r14.7 (1.1r0.15, 16r2.1) Below: 1.0 to 4.9 (0.01 0.05, 0.1 0.7) Above only: 137r14.7 (1.40r0.15, 20r2.1) Corrugated fin type 0.45 (0.48, 0.40)
Water pump
Thermostat
Radiator fan
Radiator
Pressure range in which cap valve is open
Coolant filler tank side
kPa (kg/cm2, psi)
Radiator side Fins Reservoir tank Capacity
kPa (kg/cm2, psi)
2 (US qt, Imp qt)
Coolant
Water for dilution Cooling system protective agent
Recommended materials SUBARU SUPER COOLANT (Concentrated type) SUBARU SUPER COOLANT (Diluted type) Distilled water Cooling system conditioner
Item number
Alternative
K0670Y0000 SOA345001 Soft water or tap water
CO(H4DOTC)-2
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(2)
(1)
T1
(8) (8) (7) (3) T1
(4)
T2
(5)
(6) CO-02417
(1) (2) (3) (4)
Water pump ASSY Gasket Heater by-pass hose Thermostat
(5) (6) (7) (8)
Gasket Thermostat cover Coolant filler by-pass hose Clip
Tightening torque:Nm (kgf-m, ft-lb) T1: First 12 (1.2, 8.9) Second 12 (1.2, 8.9) T2: 12 (1.2, 8.9)
CO(H4DOTC)-3
General Description
COOLING
2. RADIATOR AND RADIATOR FAN
(25) (24) (5) (27) (26) T4 (5) T4 (10) (29) T3 (5) (7) T3 (8)
(5) (6)
(11) T5 (13) T2 (4) (3) T1 (12)
(9)
(2) (14) (5) B (30) C (23) (22) (28) (1) (5) C (19) (15) B (15) T2 T4 (15) (17)
T4
(16)
T4 (21)
(18)
(15)
(20)
CO-02499
CO(H4DOTC)-4
General Description
COOLING
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Radiator lower cushion Radiator Radiator upper cushion Radiator upper bracket Clip Radiator inlet hose Engine coolant reservoir tank cap Over flow hose A Engine coolant reservoir tank Over flow pipe Radiator sub fan shroud Radiator main fan shroud Radiator sub fan ASSY (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) Radiator main fan ASSY ATF hose clip (AT model) ATF hose A (AT model) ATF hose B (AT model) ATF pipe (AT model) ATF hose C (AT model) ATF hose D (AT model) Radiator outlet hose Radiator drain plug O-ring Engine coolant filler tank Radiator cap (Engine coolant filler tank cap) (26) (27) (28) (29) (30) Coolant filler tank hose A Coolant filler tank hose B Radiator lower bracket Over flow hose B Heat shield cover (AT model)
Tightening torque:Nm (kgf-m, ft-lb) T1: 3 (0.3, 2.2) T2: 3.4 (0.3, 2.5) T3: 5 (0.5, 3.7) T4: 7.5 (0.8, 5.5) T5: 12 (1.2, 8.9)
C: CAUTION
CO(H4DOTC)-5
General Description
COOLING
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 499977100 DESCRIPTION CRANK PULLEY WRENCH REMARKS Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts. (MT model)
ST-499977100
499977400
CRANK PULLEY WRENCH
ST-499977400
499977500
CAM SPROCKET WRENCH
ST-499977500
499207400
CAM SPROCKET WRENCH
Used for removing and installing exhaust cam sprocket.
ST-499207400
CO(H4DOTC)-6
General Description
COOLING
ST1B022XU0
2. GENERAL TOOL
CO(H4DOTC)-7
Radiator Fan System

COOLING

A: WIRING DIAGRAM
BATTERY MAIN SBF SBF-6
No.3 No.4
IGNITION SWITCH No.26
MAIN FUSE BOX (M/B) B: B143 C: E: F35 F36 C10 B7 E6 E5
No.22 MAIN FAN RELAY 1
THROUGH JOINT CONNECTOR 10 F109 20 21 10 13 1 B360
MAIN FAN RELAY 2 MAIN FAN MOTOR 22 19 18 11 F17 12
SUB FAN RELAY
RELAY HOLDER F27
M
2
THROUGH JOINT CONNECTOR 16 2 1 F16 F108 7 B361 18 29 B136 ECM SUB FAN MOTOR F16 F17 1 2 B136 B: B143 C: F35 E: F36 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35 8 10 11 12 13 B361 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B360 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 F108 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 F109 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 3 4 5 6 7 9 14 15 16 17 1 2 18 19 20 21 22 F27
E M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12
1 2 4 5
3 7
CO-02317
CO(H4DOTC)-8
Radiator Fan System

COOLING
B: INSPECTION
Operating condition:
Increase: 94C (201F) or less Decrease: 91C (196F) or less Radiator fan operation OFF Low-Speed High-Speed OFF High-Speed High-Speed OFF High-Speed High-Speed OFF High-Speed High-Speed Engine coolant temperature Increase: 95 96C Increase: 97C (207F) or more (203 205F) Decrease: 92 94C Decrease: 95C (203F) or more (198 201F) Radiator fan operation Radiator fan operation Low-Speed Low-Speed High-Speed Low-Speed High-Speed High-Speed Low-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed High-Speed
Vehicle speed
A/C compressor load
During acceleration: 19 km/h (12 MPH) or less During deceleration: 10 km/h (6 MPH) or less During acceleration: 20 69 km/h (12 43 MPH) During deceleration: 11 64 km/h (7 40 MPH) During acceleration: 70 105 km/h (43 65 MPH) During deceleration: 65 103 km/h (40 64 MPH) During acceleration: 106 km/h (66 MPH) or more During deceleration: 104 km/h (65 MPH) or more
OFF Low High OFF Low High OFF Low High OFF Low High
CO(H4DOTC)-9
Radiator Fan System

COOLING
DIAGNOSIS: Radiator main fan and radiator sub fans do not rotate under the above operating conditions.
1 Step CHECK OPERATION OF RADIATOR FAN. 1) Connect the delivery (test) mode connector. 2) Turn the ignition switch to ON. 3) Using the Subaru Select Monitor, check the forced operation of the radiator fan relay. NOTE: When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution o high speed revolution o OFF in this order. Subaru Select Monitor Refer to Compulsory Valve Operation Check Mode for detailed procedures. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK OPERATION OF RADIATOR FAN. 1) Connect the delivery (test) mode connector. 2) Turn the ignition switch to ON. 3) Perform the compulsory operation check for the radiator fan relay using Subaru Select Monitor. NOTE: When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution o high speed revolution o OFF in this order. Subaru Select Monitor Refer to Compulsory Valve Operation Check Mode for detailed procedures. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Remove the sub fan relay from the relay holder. 3) Measure the voltage between the sub fan relay terminal and chassis ground. Connector & terminal (F27) No. 10 (+) Chassis ground (): CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between the sub fan relay terminal and chassis ground. Connector & terminal (F27) No. 13 (+) Chassis ground (): CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 3. 3) Check the condition of fuse. CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 22. 3) Check the condition of fuse. Check Do the radiator main fans and radiator sub fans rotate at low speed? Yes Go to step 2. No Go to step 3.
Do the radiator main fans and Radiator main fan radiator sub fans rotate at high system is normal. speed?
Go to step 27.
Go to step 4.
Go to step 5.
Go to step 7.
Go to step 6.
Replace the fuse.
Replace the fuse.
CO(H4DOTC)-10
Radiator Fan System

COOLING
Step CHECK SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 No. 11: CHECK SUB FAN RELAY. 1) Connect the battery to terminals No. 12 and No. 13 of the sub fan relay. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 No. 11: CHECK HARNESS BETWEEN SUB FAN RELAY TERMINAL AND SUB FAN MOTOR CONNECTOR. 1) Disconnect the connector from the sub fan motor. 2) Measure the resistance of harness between the sub fan relay terminal and sub fan motor connector. Connector & terminal (F16) No. 1 (F27) No. 11: CHECK HARNESS BETWEEN SUB FAN MOTOR CONNECTOR AND MAIN FAN RELAY 2 CONNECTOR. 1) Remove main fan relay 2 from the relay holder. 2) Measure the resistance of harness between sub fan motor connector and main fan relay 2 connector. Connector & terminal (F16) No. 2 (F27) No. 18: CHECK POOR CONTACT. Check poor contact of sub fan motor connector. Check Is the resistance 1 M: or more? Yes Go to step 8. No Replace the sub fan relay.
Replace the sub fan relay.
Repair the open circuit of harness between sub fan relay terminal and sub fan motor connector.
10
Repair the open circuit of the harness between sub fan motor connector and main fan relay 2 connector.
11
12
13
14
Is there poor contact in the sub Repair the poor fan motor connector? contact of sub fan motor connector. CHECK SUB FAN MOTOR. Does the radiator sub fan Go to step 13. Connect the battery positive (+) terminal to ter- rotate? minal No. 1 of the sub fan motor, and the ground () terminal to terminal No. 2. Is the resistance less than 1 :? Go to step 14. CHECK MAIN FAN RELAY 2. Measure the resistance of main fan relay 2. Terminals No. 21 No. 18: CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 :? Go to step 15. RELAY 2 AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 2 terminal and main fan motor connector. Connector & terminal (F17) No. 1 (F27) No. 2:
Go to step 12.
Replace the sub fan motor.
Replace the main fan relay 2.
Repair the open circuit of the harness between main fan relay 2 terminal and main fan motor connector.
CO(H4DOTC)-11
Radiator Fan System

COOLING
Step CHECK MAIN FAN MOTOR AND GROUND CIRCUIT. Measure the resistance between main fan motor connector and chassis ground. Connector & terminal (F17) No. 2 Chassis ground: CHECK POOR CONTACT. Check poor contact of main fan motor connector. CHECK MAIN FAN MOTOR. Connect the battery positive (+) terminal to terminal No. 1 of the main fan motor, and the ground () terminal to terminal No. 2. CHECK HARNESS BETWEEN SUB FAN RELAY AND ECM. 1) Disconnect the connectors from ECM. 2) Measure the resistance between the sub fan relay terminal and ECM connector. Connector & terminal (B136) No. 18 (F27) No. 12: CHECK POOR CONTACT. Check for poor contact of the ECM connector. Check Yes Is the resistance less than 5 :? Go to step 16. No Repair the open circuit of the harness between main fan motor connector and chassis ground. Go to step 17.
15
16
Is there poor contact in the main fan motor connector? Does the radiator main fan rotate?
17
Repair the poor contact of main fan motor connector. Go to step 18. Replace the main fan motor.
18
Repair the open circuit of harness between sub fan relay terminal and ECM.
19
20
21
22
23
CHECK MAIN FAN RELAY 1. 1) Turn the ignition switch to OFF. 2) Remove main fan relay 1 from the main fuse box. 3) Measure the resistance of terminal in main fan relay 1 switch. CHECK MAIN FAN RELAY 1. 1) Connect the main fan relay 1 coil side terminal to the battery. 2) Measure the resistance between terminals of main fan relay 1 switch. CHECK HARNESS BETWEEN MAIN FAN RELAY 1 AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 1 terminal and main fan motor connector. Connector & terminal (F17) No. 1 (F36) No. 6: CHECK HARNESS BETWEEN MAIN FAN RELAY 1 AND ECM. 1) Disconnect the connectors from ECM. 2) Measure the resistance between main fan relay 1 terminal and ECM connector. Connector & terminal (B136) No. 29 (B143) No. 7:
Go to step 21.
Check the DTC. Repair the trouble cause. <Ref. to EN(H4DOTC)(diag )-42, Read Diagnostic Trouble Code (DTC).> Replace the main fan relay 1.
Repair the open circuit of the harness between main fan relay 1 terminal and main fan motor connector.
Repair the open circuit of the harness between main fan relay 1 terminal and ECM.
CO(H4DOTC)-12
Radiator Fan System

COOLING
Step CHECK HARNESS BETWEEN MAIN FAN RELAY 2 AND ECM. Measure the resistance between main fan relay 2 terminal and ECM connector. Connector & terminal (B136) No. 29 (F27) No. 22: CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 4 and 26. 3) Check the condition of fuse. CHECK POOR CONTACT. Check for poor contact of the ECM connector. CHECK OPERATION OF RADIATOR FAN. If the both fans do not rotate at high speed in the condition of step 2, check whether the radiator sub fan is rotating. CHECK GROUND CIRCUIT OF MAIN FAN RELAY 2. 1) Remove the main fan relay 2 from the relay holder. 2) Measure the resistance between main fan relay 2 terminal and chassis ground. Connector & terminal (F27) No. 19 Chassis ground: CHECK POWER SUPPLY TO MAIN FAN RELAY 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between main fan relay 2 terminal and chassis ground. Connector & terminal (F27) No. 20 (+) Chassis ground (): CHECK MAIN FAN RELAY 2. 1) Turn the ignition switch to OFF. 2) Remove the main fan relay 2. 3) Measure the resistance of main fan relay 2. Terminals (F27) No. 18 (F27) No. 19: CHECK MAIN FAN RELAY 2. 1) Connect the battery to terminals No. 20 and No. 22 of the main fan relay 2. 2) Measure the resistance of main fan relay 2. Terminals (F27) No. 18 (F27) No. 19: Check Yes Is the resistance less than 1 :? Go to step 25. No Repair the open circuit of the harness between main fan relay 2 terminal and ECM. Go to step 26.
24
25
Replace the fuse.
26
Is there poor contact in ECM connector? Does the radiator sub fan rotate?
27
Repair the poor contact of ECM connector. Go to step 20.
Repair the power supply circuit to the main fuse box. Go to step 28.
28
Repair the open circuit of harness between main fan relay 2 and chassis ground.
29
Go to step 30.
30
Go to step 31.
31
CO(H4DOTC)-13
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Remove the drain plug to drain engine coolant into container. NOTE: Remove the coolant filler tank cap so that engine coolant will drain faster.
NOTE: When pouring the engine coolant, the radiator side cap must not be removed. The SUBARU Super Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum cylinder block. Always use SUBARU Super Coolant, since other coolant may cause corrosion. 3) Fill engine coolant into the reservoir tank up to FULL level.
FULL LOW
CO-02492
CO-00248

1) Pour cooling system conditioner through the filler neck. Cooling system protective agent: Refer to SPECIFICATION for the cooling system protective agent. <Ref. to CO(H4DOTC)-2, SPECIFICATION, General Description.> 2) Fill the engine coolant into coolant filler tank up to the filler neck position. Recommended engine coolant: Refer to SPECIFICATION for the recommended engine coolant. <Ref. to CO(H4DOTC)-2, SPECIFICATION, General Description.> Coolant level: Refer to SPECIFICATION for the amount of engine coolant. <Ref. to CO(H4DOTC)-2, SPECIFICATION, General Description.> Engine coolant concentration: Refer to ADJUSTMENT for the engine coolant concentration. <Ref. to CO(H4DOTC)-15, ADJUSTMENT, Engine Coolant.> CAUTION: Do not confuse the cap of coolant filler tank and cap of radiator.
4) Close the coolant filler tank cap, and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.) 5) Wait for one minute after the engine stops, then open the coolant filler tank cap. If the engine coolant level drops, add engine coolant into the coolant filler tank up to the filler neck position. 6) Perform the procedures 4) and 5) again. 7) Install the coolant filler tank cap and reservoir tank cap properly. 8) Start the engine and operate the heater at maximum hot position and the blower speed setting to LO. 9) Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: Be careful with the engine coolant temperature gauge to prevent overheating. 10) Stop the engine and wait until the engine coolant temperature lowers to 30C (86F) or less. 11) Open the coolant filler tank cap. If the engine coolant level drops, add engine coolant into the coolant filler tank up to the filler neck position and into the reservoir tank up to the FULL level. 12) Install the coolant filler tank cap and reservoir tank cap properly. 13) Set the heater setting to maximum hot position and the blower speed setting to LO and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step 9).
CO(H4DOTC)-14
Engine Coolant
COOLING
B: ADJUSTMENT
CAUTION: SUBARU Super Coolant concentration must be used from 50 to 60% to assure the best performance of the anti-freeze and anti-rust agents. To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper SUBARU Super Coolant concentration in the table, and add diluting water to the SUBARU Super Coolant (concentrated type) until it reaches the proper dilution.
Recommended engine coolant and water for dilution: Refer to SPECIFICATION for the recommended engine coolant and diluting water. <Ref. to CO(H4DOTC)-2, SPECIFICATION, General Description.>
CO(H4DOTC)-15
Water Pump
COOLING
4. Water Pump
A: REMOVAL
1) Remove the collector cover. 2) Remove the radiator. <Ref. to CO(H4DOTC)-20, REMOVAL, Radiator.> 3) Remove the V-belts. <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> 4) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.> 5) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> 6) Remove the timing belt. <Ref. to ME(H4DOTC)47, REMOVAL, Timing Belt.> 7) Remove the automatic belt tension adjuster (A). 8) Remove the belt idler (B). 9) Remove the belt idler No. 2 (C).
14) Remove the water pump.
CO-00021
B: INSTALLATION
1) Install the water pump onto cylinder block LH. NOTE: Use a new gasket. When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: First: 12 Nm (1.2 kgf-m, 8.9 ft-lb) Second: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
(B) (C)
(A) (B)
(C) CO-00023
(A) (D)
10) Remove the cam sprocket LH. <Ref. to ME(H4DOTC)-56, REMOVAL, Cam Sprocket.> 11) Remove the belt cover No. 2 LH.
(E)
(F)
ME-02463
2) Install the hose to water pump. 3) Install the tensioner bracket. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
CO-00024
CO-00025
CO-00025
13) Disconnect the hose from water pump.
CO(H4DOTC)-16
Water Pump
COOLING
4) Install the belt cover No. 2 LH. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
C: INSPECTION
1) Check the water pump bearing for smooth rotation. 2) Check the water pump pulley for abnormalities. 3) Make sure the impeller is not abnormally deformed or damaged. 4) Inspect the clearance between impeller and pump case. Clearance between impeller and pump case: Standard 0.5 1.5 mm (0.020 0.059 in)
CO-00024
5) Install the cam sprocket LH. <Ref. to ME(H4DOTC)-56, INSTALLATION, Cam Sprocket.> 6) Install the belt idler No. 2 (C). Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb) 7) Install the belt idler (B).
CO-00293
Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 8) Install an automatic belt tension adjuster (A) with the tension rod held by a pin. <Ref. to ME(H4DOTC)-49, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.>
5) After water pump installation, check pulley shaft for engine coolant leaks or noise. If leaks or noise are noted, replace the water pump assembly.
(A) (B)
(C) CO-00023
9) Install the timing belt. <Ref. to ME(H4DOTC)-50, TIMING BELT, INSTALLATION, Timing Belt.> 10) Install the timing belt cover. <Ref. to ME(H4DOTC)-46, INSTALLATION, Timing Belt Cover.> 11) Install the crank pulley. <Ref. to ME(H4DOTC)44, INSTALLATION, Crank Pulley.> 12) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.> 13) Install the radiator. <Ref. to CO(H4DOTC)-21, INSTALLATION, Radiator.> 14) Install the collector cover.
CO(H4DOTC)-17
Thermostat
COOLING
5. Thermostat
A: REMOVAL
1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine coolant completely. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 5) Disconnect the radiator outlet hose from thermostat cover.
B: INSTALLATION
1) Install a gasket to thermostat. NOTE: Use a new gasket. 2) Install the thermostat and thermostat cover. NOTE: Install with the jiggle pin facing upward. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
CO-02124
6) Remove the thermostat cover, and then remove the gasket and thermostat.
T
(D)
(C) (B)
(A) CO-02337
(A) Thermostat cover (B) Gasket (C) Thermostat (D) Jiggle pin
(C) (B)
(A) CO-02336
3) Connect the radiator outlet hose to thermostat cover. 4) Install the under cover. 5) Lower the vehicle. 6) Fill engine coolant. <Ref. to CO(H4DOTC)-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
(A) Thermostat cover (B) Gasket (C) Thermostat
CO(H4DOTC)-18
Thermostat
COOLING
C: INSPECTION
Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results. Inspection method Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for even temperature distribution. The measured value should meet the specification. NOTE: Leave the thermostat in the boiling water for five minutes or more before measuring the valve lift. Hold the thermostat with a wire or the like to avoid contacting with container bottom. Opening start temperature: 76 80C (169 176F) Full open temperature: 91C (196F) Total valve lift: 9.0 mm (0.354 in) or more
(A)
(B)
CO-02420
CO(H4DOTC)-19
Radiator
COOLING
6. Radiator
A: REMOVAL
CAUTION: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
8) Disconnect the connectors of main fan motor connector (A) and sub fan motor connector (B).
(A)
CO-00251
(B)
IN-00203
4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the heat shield cover from radiator. (AT model)
CO-00252
9) Disconnect the radiator outlet hose from thermostat cover.
CO-02355
7) Drain engine coolant completely. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO-02124
10) Disconnect the ATF cooler hoses from ATF pipes. (AT model) NOTE: Plug the ATF pipe to prevent ATF from leaking.
CO-00253
11) Lower the vehicle. 12) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 13) Remove the reservoir tank. <Ref. to CO(H4DOTC)-29, REMOVAL, Reservoir Tank.>
CO(H4DOTC)-20
Radiator
COOLING
14) Disconnect the radiator inlet hose (A) from the radiator. 15) Remove the hood stay holder (B).
(A)
B: INSTALLATION
1) Attach the radiator lower cushion to the hole on the radiator lower bracket.
(B) CO-00255
CO-00041
16) Disconnect the two coolant filler tank hoses from the radiator.
2) Install the radiator to vehicle. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side. 3) Install the radiator upper brackets and tighten the bolts. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
CO-00256
17) Remove the radiator upper brackets.
CO-00040
4) Connect the two coolant filler tank hoses to the radiator.

CO-00040
18) Move the radiator to the left while lifting it upward. 19) Lift the radiator up and away from vehicle.
CO-00256
5) Connect the radiator inlet hose (A).
CO(H4DOTC)-21
Radiator
COOLING
6) Install the hood stay holder (B). Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
(A)
12) Connect the connectors of main fan motor connector (A) and sub fan motor connector (B).
(A)
(B) CO-00255
CO-00251
7) Install the reservoir tank. <Ref. to CO(H4DOTC)-29, INSTALLATION, Reservoir Tank.> 8) Install the air intake duct. <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.> 9) Lift up the vehicle. 10) Connect the ATF cooler hoses. (AT model)
(B)
CO-00252
13) Install the heat shield cover to the radiator. (AT model) Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb)
CO-00253
CO-02355
CO-02124
IN-00203
17) Fill engine coolant. <Ref. to CO(H4DOTC)-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO(H4DOTC)-22
Radiator
COOLING
18) Check the ATF level. (AT model) <Ref. to 5AT28, INSPECTION, Automatic Transmission Fluid.> 19) Install the collector cover.
C: INSPECTION
1) Remove the coolant filler tank cap, fill the coolant filler tank with engine coolant, then install the tester to the installation position of the cap.
CO-02244
2) Apply a pressure of 122 kPa (1.2 kg/cm2, 18 psi) to the radiator and check the following points: Leakage from the radiator or its vicinity Leakage from the hose or its connections CAUTION: Inspection must be carried out at the side of coolant filler tank, not at the side of radiator. Engine should be turned off. Wipe engine coolant from check points in advance. Be careful of the spurt of engine coolant when removing the tester. Be careful not to deform the filler neck of the coolant filler tank when installing and removing the tester.
CO(H4DOTC)-23
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
CO-00044
2) Increase pressure until the tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Remove the cap if it is opened under a pressure less than the service limit value Coolant filler tank side Specification: 93 123 kPa (0.95 1.25 kg/cm2, 14 18 psi) Service limit: 83 kPa (0.85 kg/cm2, 12 psi) Radiator side Specification: 122 152 kPa (1.24 1.55 kg/cm2, 18 22 psi) Service limit: 112 kPa (1.14 kg/cm2, 16 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect. Do not confuse the cap of coolant filler tank and cap of radiator.
CO(H4DOTC)-24

COOLING

A: REMOVAL
9) Remove the ATF hose from the hose clip of the radiator main fan motor assembly. (AT model)
CO-02375
IN-00203
4) Lift up the vehicle. 5) Remove the under cover. 6) Disconnect the main fan motor connector (A).
(A)
10) Lower the vehicle. 11) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 12) Remove the reservoir tank. <Ref. to CO(H4DOTC)-29, REMOVAL, Reservoir Tank.> 13) Remove the bolts that hold the radiator main fan motor assembly and the over flow pipe.
CO-02494 CO-00251
7) Remove the heat shield cover from radiator. (AT model)
(A)
(B) CO-00255 CO-02355
8) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
16) Remove the radiator main fan motor assembly from the upper side of the vehicle.
CO(H4DOTC)-25

COOLING
B: INSTALLATION
3) Remove the bolts holding the main fan motor onto the radiator main fan shroud.
CO-00098
D: ASSEMBLY
CO-02493
CO-02494
Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb) Tightening torque: 3.4 Nm (0.3 kgf-m, 2.5 ft-lb)
CO-00098
CO-02355
C: DISASSEMBLY
1) Remove the clip holding the main fan motor connector on the radiator main fan shroud. 2) Remove the nuts holding the radiator main fan to the main fan motor.
CO-02142
CO-02142
CO(H4DOTC)-26

COOLING

A: REMOVAL
11) Remove the bolts that hold the radiator sub fan motor assembly and the over flow pipe.
CO-02495
IN-00203 (A)
4) Lift up the vehicle. 5) Remove the under cover. 6) Disconnect the sub fan motor connector (B).
(B) (B) CO-00255
14) Remove the radiator sub fan motor assembly from the vehicle.
CO-00252
7) Remove the heat shield cover from radiator. (AT model)
CO-02355
8) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 9) Lower the vehicle. 10) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
CO(H4DOTC)-27

COOLING
B: INSTALLATION
3) Remove the bolts holding the sub fan motor to the radiator sub fan shroud.
CO-00098
D: ASSEMBLY
CO-02493
CO-02495
Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb) Tightening torque: 3.4 Nm (0.3 kgf-m, 2.5 ft-lb)
CO-00098
CO-02355
C: DISASSEMBLY
1) Remove the clip holding the sub fan motor connector on the radiator sub fan shroud. 2) Remove the nuts holding the radiator sub fan to the sub fan motor.
CO-02143
CO-02143
CO(H4DOTC)-28
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
1) Pull out the over flow hose (A). 2) Pull out the reservoir tank to the arrow direction while pushing the claw (B).
(B)
(A)
CO-02457
B: INSTALLATION
C: INSPECTION
CO(H4DOTC)-29
Coolant Filler Tank

COOLING
11.Coolant Filler Tank

A: REMOVAL
WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Remove the collector cover. 2) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of coolant. <Ref. to CO(H4DOTC)-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 3) Disconnect the engine coolant hoses from coolant filler tank. 4) Remove the bolts which install the coolant filler tank.
CO-02392
5) Disconnect the engine coolant hose which connects the under side of coolant filler tank. 6) Remove the coolant filler tank.
B: INSTALLATION
CO-02393
CO(H4DOTC)-30

COOLING

A: INSPECTION
Trouble Possible cause a. Insufficient engine coolant b. Loose timing belt c. Oil on drive belt d. Malfunction of thermostat e. Malfunction of water pump f. Clogged engine coolant passage g. Improper ignition timing h. Clogged or leaking radiator Overheating i. Engine oil mixed in engine coolant j. Air/fuel mixture ratio too lean k. Excessive back pressure in exhaust system l. Insufficient clearance between piston and cylinder m. Slipping clutch n. Dragging brake o. Defective radiator fan Over-cooling a. Ambient temperature extremely low b. Defective thermostat a. Loosened or damaged connecting units on hoses b. Leakage from water pump c. Leakage from water pipe d. Leakage around cylinder head gasket e. Damaged or cracked cylinder head and cylinder block f. Damaged or cracked thermostat cover g. Leakage from radiator a. Timing belt problem b. Defective radiator fan c. Defective water pump bearing d. Defective water pump mechanical seal Corrective action Replenish engine coolant, inspect for leakage, and repair it if necessary. Repair or replace timing belt tensioner. Replace. Replace. Replace. Clean. Inspect and repair ignition control system. <Ref. to EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.> Clean, repair or replace. Replace engine coolant. If there is no improvement, check, repair and replace the engine. Inspect and repair the fuel injection system. <Ref. to EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.> Clean or replace. Adjust or replace. Repair or replace. Adjust. Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them. Partly cover radiator front area. Replace. Repair or replace. Replace. Repair or replace. Retighten cylinder head bolts or replace gasket. Repair or replace. Repair or replace. Repair or replace. Replace. Replace. Replace water pump. Replace water pump.
Noise
CO(H4DOTC)-31

COOLING
CO(H4DOTC)-32
General Description
LUBRICATION
A: SPECIFICATION
Specifications for the turbo model are included in the LU (H4SO) section. <Ref. to LU(H4SO)-2, General Description.>
LU(H4DOTC)-2
General Description
A: SPECIFICATION
Specifications for the turbo model are the same as the SOHC model. <Ref. to SP(H4SO)-2, General Description.>
SP(H4DOTC)-2
General Description
IGNITION
A: SPECIFICATION
Item Ignition coil Type Ignition system Manufacturer Manufacturer and type Thread size (diameter, pitch, length) Spark plug gap Electrode Specification FK0334 Independent ignition coil Diamond Electric NGK: SILFR6A 14, 1.25, 26.5 0.7 0.8 (0.028 0.031) Iridium
Spark plug
mm mm (in)
B: COMPONENT
T2
T1
(2) (1)
T1 (1) (2)
T2
IG-02079
(1)
Spark plug
(2)
Ignition coil
IG(H4DOTC)-2
General Description
IGNITION
C: CAUTION
IG(H4DOTC)-3
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
Spark plug: Refer to SPECIFICATION for the spark plug. <Ref. to IG(H4DOTC)-2, SPECIFICATION, General Description.>
2. LH SIDE
1) Remove the collector cover. 2) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 3) Disconnect the air duct from the secondary air pump. 4) Remove the bolts attaching the air duct to the rocker cover LH and raise the air duct.
1. RH SIDE
IN-00203
3) Remove the air cleaner case. <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.> 4) Disconnect the connector from ignition coil. 5) Remove the ignition coil. NOTE: Turn #3 ignition coil by 180 degrees to remove it.
IG-02067
5) Disconnect the connector from ignition coil. 6) Remove the ignition coil. NOTE: Turn #4 ignition coil by 180 degrees to remove it.
IG-02091
IG-02089
IG(H4DOTC)-4
Spark Plug
IGNITION
B: INSTALLATION
1. RH SIDE
Install in the reverse order of removal. Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.6 kgf-m, 11.8 ft-lb)
2. LH SIDE
Install in the reverse order of removal. Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.6 kgf-m, 11.8 ft-lb) Tightening torque (Air duct): 9 Nm (0.9 kgf-m, 6.6 ft-lb)
IG-00012
3) Oil fouled: Wet black deposits show oil entrance into the combustion chamber through worn rings and excessive clearance between valve guides and stems.
C: INSPECTION
(E) (C)
IG-00013 (B) (A) IG-02010 (D)
(A) (B) (C) (D) (E)
Spark plug gap Carbon accumulation or wear Crack Damage Damaged gasket
IG-00014
IG-00011
IG(H4DOTC)-5
Spark Plug
IGNITION
D: ADJUSTMENT
Clean up the spark plug using nylon brush or equivalent. Clean and remove the carbon or oxide deposits. If deposits are too stubborn, replace the spark plugs. After cleaning the spark plugs, measure the spark plug gap using a gap gauge. NOTE: Never use a plug cleaner. Never use a metal brush because it makes insulator worn. Spark plug gap : L 0.7 0.8 mm (0.028 0.031 in)
IG-02035
IG(H4DOTC)-6
Ignition Coil
IGNITION
3. Ignition Coil
A: REMOVAL
Direct ignition type has been adopted. Refer to Spark Plug, REMOVAL for removal procedures. <Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
C: INSPECTION
For inspection procedure, refer to Diagnostics for Engine Starting Failure. <Ref. to EN(H4DOTC)(diag)-73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
IG(H4DOTC)-7
Ignition Coil
IGNITION
IG(H4DOTC)-8
General Description
A: SPECIFICATION
Specifications for the turbo model are included in the SC (H4SO) section. <Ref. to SC(H4SO)-2, General Description.>
SC(H4DOTC)-2


A: PROCEDURE
1. ENGINE
1 Step Check CHECK ENGINE START FAILURE. Does the engine start? 1) Ask the customer when and how the trouble occurred using the interview checklist. <Ref. to EN(H4DOTC)(diag)-3, CHECK, Check List for Interview.> 2) Start the engine. Yes Go to step 2. No Inspection using Diagnostics for Engine Start Failure. <Ref. to EN(H4DOTC)(diag) -66, Diagnostics for Engine Starting Failure.> Inspection using General Diagnostic Table <Ref. to EN(H4DOTC)(diag) -370, General Diagnostic Table.> Inspection using Diagnostics Procedure for Subaru Select Monitor Communication. <Ref. to EN(H4DOTC)(diag) -79, Diagnostic Procedure for Subaru Select Monitor Communication.>
Repair the related parts. NOTE: If DTC is not shown on display although the malfunction indicator light illuminates, perform the diagnosis of malfunction indicator light circuit or combination meter. <Ref. to EN(H4DOTC)(diag)-57, Malfunction Indicator Light.> PERFORM DIAGNOSIS. Is DTC displayed on the Subaru Inspect using Finish the diagno1) Perform the Clear Memory Mode. <Ref. to Select Monitor or general scan Diagnostic Proce- sis. EN(H4DOTC)(diag)-52, Clear Memory Mode.> tool? dure with Diagnos2) Perform the Inspection Mode. <Ref. to tic Trouble Code EN(H4DOTC)(diag)-43, Inspection Mode.> (DTC)<Ref. to EN(H4DOTC)(diag) -89, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CHECK THE COMMUNICATION STATUS. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor or general scan tool to the data link connector. 3) Turn the ignition switch to ON, and run the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed procedures, refer to Subaru Select Monitor. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK DTC. Read DTC using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR Refer to Read Diagnostic Trouble Code for detailed operation procedure. <Ref. to EN(H4DOTC)(diag)-42, Read Diagnostic Trouble Code (DTC).> General scan tool For detailed operation procedures, refer to the general scan tool operation manual.
Is DTC displayed on the Subaru Record the DTC. Select Monitor or general scan Repair the trouble tool? cause. <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> Go to step 5.
EN(H4DOTC)(diag)-2


A: CHECK
1. CHECK LIST NO. 1
Place
Engine temperature
ON/ ON/ ON/ ON/ ON/
OFF OFF OFF OFF OFF
EN(H4DOTC)(diag)-3

2. CHECK LIST NO. 2

Yes /
No
Yes /
No
EN(H4DOTC)(diag)-4
General Description
A: CAUTION
1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay. CAUTION: Do not use the electrical test equipment on airbag system circuits. Be careful not to damage the airbag system wiring harness when servicing the ECM, TCM, main relay and fuel pump relay. 2) Never connect the battery in reverse polarity. Failure to do so will damage the ECM instantly, and other parts will also be damaged. 3) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as ECM etc. 4) Before disconnecting the connectors of each sensor and ECM, be sure to turn the ignition switch to OFF. Perform the Clear Memory Mode after connecting the connectors. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 5) When measuring the voltage or resistance of individual sensor or all electrical control modules, use a tapered pin with a diameter of less than 0.6 mm (0.024 in). Do not insert the pin 4 mm (0.16 in) or more into the part. CAUTION: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system. NOTE: When replacing the ECM of the models with Immobilizer, immobilizer system must be registered. To do so, all ignition keys and ID cards need to be prepared. Refer to the PC application help for Subaru Select Monitor. 6) Take care not to allow water to get into the connector when servicing the vehicle in rainy weather or when washing the vehicle. Avoid exposure to water even if the connectors are waterproof.
(A)
EN-00069
(A) Stud bolt
FU-01170
9) Every engine control system-related part is a precision part. Do not drop them. 10) Observe the following cautions when installing a radio in vehicle. CAUTION: The antenna must be kept as far apart as possible from control module. (ECM is installed under the passenger's side floor mat.) The antenna feeder must be placed as far apart as possible from the ECM and engine control system harness. Carefully adjust the antenna for correct matching. When mounting a large power type radio, pay special attention to the three items mentioned above. Incorrect installation of the radio may affect the operation of ECM. 11) When disconnecting the fuel hose, release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
EN(H4DOTC)(diag)-5
General Description
C: NOTE
B: INSPECTION
1. BATTERY
2. ENGINE GROUND
FU-01170
EN(H4DOTC)(diag)-6
General Description
D: PREPARATION TOOL
ST1B022XU0
499987500
CRANKSHAFT SOCKET
ST-499987500
EN(H4DOTC)(diag)-7


A: LOCATION
1. CONTROL MODULE
(3) (1)
(4)
(2)
EN-03145
(1) (2)
(3)
(4)
Data link connector
(1)
EN-01147
(2)
EN-05065
(4) (3)
EN-02975
AT-01877
EN(H4DOTC)(diag)-8

2. SENSOR
(7)
(5)
(1)
(2)
(3)
(8)
(5)
(8)
(6)
(4)
EN-05066
(1) (2) (3)
Manifold absolute pressure sensor Engine coolant temperature sensor Electronic throttle control
(4) (5) (6)
Knock sensor Intake camshaft position sensor Crankshaft position sensor
(7) (8)
Mass air flow and intake air temperature sensor Tumble generator valve ASSY
EN(H4DOTC)(diag)-9

(1) (2)
EN-01927
EN-00295
(4)
(3) EN-01928 (6) (5) EN-02169
EN-01798
EN-02919
(8)
(7)
EN-02920
EN-05373
EN(H4DOTC)(diag)-10

(1)
(2)
(3)
(4)
EN-06854
(1) (2)
Front oxygen (A/F) sensor Front catalytic converter
(3)
Rear oxygen sensor
(4)
Rear catalytic converter
(1)
(2) EN-00303 EN-01800
(3)
(4)
EN-01933
EN(H4DOTC)(diag)-11

(1) (2)
(3)
(4) EN-03146
(1) (2)
(3)
(4)
(3)
(1)
(2) EN-03147 EN-03003
(4)
EN-03132
EN(H4DOTC)(diag)-12

(4)
(5)
(1) (2)
(3)
(9) (8)
(5) (4)
(7) (9)
(6)
EN-05068
(1) (2) (3)
Wastegate control solenoid valve Purge control solenoid valve 2 Purge control solenoid valve 1
(4) (5) (6)
Ignition coil Intake oil flow control solenoid valve Secondary air pump
(7) (8) (9)
Secondary air combination valve RH Secondary air combination valve LH Tumble generator valve ASSY
EN(H4DOTC)(diag)-13

(3)
(1)
(2)
EN-01935
EN-05069
(4)
(5) EN-05070 EN-05071
(6)
(7)
EN-04936
EN-04990
(8)
(9)
EN-04991
EN-04992
EN(H4DOTC)(diag)-14

(1)
(2)
(3)
(4)
EN-03938
(1) (2)
(3)
Drain valve
(4)
Drain filter
(4) (3)
(2) (1) EN-02980 EN-02981
EN(H4DOTC)(diag)-15

(5) (4) (3) (2)
(11) (10) (9)
(8)
(7)
(6)
(1)
EN-05721
(1) (2) (3) (4) (5)
Starter Fuel pump Main relay Fuel pump relay Electronic throttle control relay
(6) (7) (8) (9)
Radiator main fan relay 1 Radiator sub fan relay Radiator main fan relay 2 Secondary air combination valve relay 1
(10) (11)
Secondary air combination valve relay 2 Secondary air pump relay
(2) (1)
EN-05614
EN-02093
(4)
(8) (3) (5) EN-03150 (6) (9) (10) (11) (7) EN-05073
EN(H4DOTC)(diag)-16


TO A:
B134 2 1 10 9 8 20 19 18 30 29 28
TO B:
B135
TO C:
B136
TO D:
B137
7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31
7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28
6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 17 30 29 28 35 34 33 32 31
7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26
EN-05288
Contents Signal (+) Signal () Shield Signal Shield Ground (sensor) Signal 1
Connector No. B134 B134 B134 B135 B135 B135 B136 B136 B136 B134 B134 B135 B135 B135 B135 B137 B136 B136 B135 B136 B135
Terminal No. 13 14 24 4 1 30 3 2 4 34 29 26 35 34 18 27 32 24 19 31 27
Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 0 0 0 0 0 0 13 1.0 1.4 0 0 0 0.3 4.6 0 or 10 13 0 ON: 10 13 OFF: 0 10 13 ON: 0 OFF: 10 13 10 13 7 +7 0 0 0 0.9 0 0 12 14 1.0 1.4 0 0.3 4.5 0 0 0.3 4.6 0 or 12 14 0 ON: 12 14 OFF: 0 12 14 ON: 0 OFF: 12 14 13 14
Note Waveform Waveform Waveform Waveform After engine is warmed up. After engine is warmed up. Waveform Cranking: 8 14 When connected: 0
Rear oxygen sensor
Front oxygen (A/F) sensor Signal 2 heater Rear oxygen sensor heater signal Engine coolant temperature sensor Signal
Ground (sensor) Signal Air flow sensor Shield Ground Intake air temperature sensor signal Wastegate control solenoid valve Starter switch A/C switch Ignition switch Neutral position switch (AT / MT) Delivery (test) mode connector
EN(H4DOTC)(diag)-17

Connector No. B134 B134 B135 B134 B135 B134 B137 B137 B137 B137 B137 B137 B137 B137 B135 B136 B136 B136 B136 B136 B136 B137 B136 B134 B134 B134 B134 B135 B135 B135 B136 B134 B134 B134 Terminal No. 15 25 5 7 2 19 18 19 20 21 8 9 10 11 33 12 9 18 29 11 22 29 7 6 19 29 33 9 8 1 16 21 11 22 Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 2.8 2.8 0 0 10 13 10 13 10 13 5 0 0 0 0 10 13 10 13 10 13 10 13 10 13 0 or 5 ON: 0.5 or less OFF: 10 13 ON: 0.5 or less OFF: 10 13 ON: 0.5 or less OFF: 10 13 ON: 1 or less OFF: 10 13 ON: 1 or less OFF: 10 13 1.7 2.4 5 0 10 13 2.8 3.2 2.4 2.7 0 1 or less mo 4 or more 0 or 5 0 or 5 0 12 14 12 14 12 14 5 12 14 12 14 12 14 12 14 1 14 1 14 1 14 1 14 12 14 0 or 5 ON: 0.5 or less OFF: 12 14 ON: 0.5 or less OFF: 12 14 ON: 0.5 or less OFF: 12 14 0 13 or more ON: 1 or less OFF: 12 14 ON: 1 or less OFF: 12 14 1.1 1.6 5 0 ON: 0 OFF: 12 14 2.8 3.2 2.4 2.7 0 1 or less mo 4 or more 0 or 5 0 or 5 0 Waveform Waveform
Contents Signal Shield
Note Ignition switch OFF: 10 13 Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Model with A/C only Light ON: 1 or less Light OFF: 10 14 Waveform Waveform Waveform
Knock sensor
Back-up power supply Control module power supply Sensor power supply #1 #2 Ignition control #3 #4 #1 #2 Fuel injector #3 #4 Fuel pump con- Signal 1 trol unit Signal 2 A/C relay control Radiator fan relay 1 control Radiator fan relay 2 control Malfunction indicator light Engine speed output Purge control solenoid valve 1 Purge control solenoid valve 2 Manifold absolute pressure sensor Signal Power supply Ground (sensor) Power steering oil pressure switch Front oxygen (A/F) sensor signal (+) Front oxygen (A/F) sensor signal () Front oxygen (A/F) sensor shield SSM communication line Intake camshaft position sensor (LH) Intake camshaft position sensor (RH) Intake camshaft position sensor ground
EN(H4DOTC)(diag)-18

Connector No. Terminal No. Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0.64 0.72 0.64 0.72 (After engine is Fully opened: 3.96 warmed up.) 1.51 1.58 Fully opened: 4.17 5 0 Duty waveform Duty waveform 10 13 ON: 0 OFF: 10 13 ON: 10 13 OFF: 0 0 ON: 10 13 OFF: 0 0 Fully closed: 1 Fully opened: 3.3 5 0 0 Fully closed: 1 Fully opened: 3.3 5 0 ON: 0 OFF: 10 13 ON: 0 OFF: 10 13 When clutch pedal is depressed: 0 When clutch pedal is released: 10 13 When brake pedal is depressed: 0 When brake pedal is released: 10 13 When brake pedal is depressed: 10 13 When brake pedal is released: 0 1.51 1.58 (After engine is warmed up.) 5 0 Duty waveform Duty waveform 12 14 ON: 0 OFF: 12 14 ON: 12 14 OFF: 0 0 ON: 12 14 OFF: 0 0 Fully closed: 1 Fully opened: 3.3 5 0 0 Fully closed: 1 Fully opened: 3.3 5 0 ON: 0 OFF: 12 14 ON: 0 OFF: 12 14 When clutch pedal is depressed: 0 When clutch pedal is released: 12 14 When brake pedal is depressed: 0 When brake pedal is released: 12 14 When brake pedal is depressed: 12 14 When brake pedal is released: 0
Contents
Note
Main
B134
18
Fully closed: 0.6 Fully opened: 3.96 Fully closed: 1.48 Fully opened: 4.17 Drive frequency: 500 Hz Drive frequency: 500 Hz When ignition switch is turned to ON: ON ON: cranking
Electric throttle control
Sub
B134 B134 B134 B137 B137 B136 B136 B137 B137 B137 B137 B135 B135 B135 B136 B135 B135 B135 B136 B136
28 19 29 5 4 1 21 15 14 17 16 23 21 29 6 31 22 30 20 33
Power supply Ground (sensor) Electronic throttle control motor (+) Electronic throttle control motor () Electronic throttle control motor power supply Electronic throttle control motor relay Intake AVCS solenoid (LH) Intake AVCS solenoid (RH) Signal (+) Signal () Signal (+) Signal () Main sensor signal Main power supply Ground (main sensor) Shield Sub sensor signal Sub power supply Ground (sub sensor)
Starter relay A/C middle pressure switch
Clutch switch
B136
25
Brake switch 1
B135
20
Brake switch 2
B135
28
EN(H4DOTC)(diag)-19

Connector No. Terminal No. Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) When not operating: When not operating: 3.5 4.5 3.5 4.5 When operating When operating RES/ACC: 2.5 3.5 RES/ACC: 2.5 3.5 When operating SET/ When operating SET/ COAST: 0.5 1.5 COAST: 0.5 1.5 When operating When operating CANCEL 0 0.5 CANCEL: 0 0.5 ON: 0 OFF: 5 2.3 2.7 ON: 1 or less OFF: 10 13 ON: 1 or less OFF: 10 13 2.5 3.8 0 0 Fully closed: 0.4 1.2 Fully opened: 2.8 4.6 Fully closed: 0.4 1.2 Fully opened: 2.8 4.6 0 or 10 13 0 or 10 13 0 or 10 13 0 or 10 13 2.2 2.8 5.12 0 ON: 0 OFF: 10 13 ON: 0 OFF: 10 13 ON: 0 OFF: 10 13 10 13 0 0 ON: 0 OFF: 5 2.3 2.7 ON: 1 or less OFF: 12 14 ON: 1 or less OFF: 12 14 2.5 3.8 0 0 Fully closed: 0.4 1.2 Fully opened: 2.8 4.6 Fully closed: 0.4 1.2 Fully opened: 2.8 4.6 0 or 12 14 0 or 12 14 0 or 12 14 0 or 12 14 2.2 2.8 5.12 0 ON: 0 OFF: 12 14 ON: 0 OFF: 12 14 ON: 0 OFF: 12 14 12 14 0 0
Contents
Note
B135
24
Cruise control main switch Fuel tank pressure sensor Pressure control solenoid valve Drain valve Fuel temperature sensor Signal 1 Signal 2 CAN communication (+) CAN communication () AT/MT identification Immobilizer Blow-by leak diagnosis signal Tumble generator valve position sensor signal (RH)
B135 B135 B136 B136 B135 B136 B136 B136 B136 B136 B134
12 32 28 17 17 26 34 27 35 15 30
Ambient temperature: 25C (77F) At the time of open circuit (fault): 5
B134
26
Tumble generator valve position sensor signal (LH) Tumble generator valve RH (closed) Tumble generator valve LH (closed) Tumble generator valve RH (open) Tumble generator valve LH (open) Secondary air pipe pressure sensor Signal
B134
16
B137 B137 B137 B137 B134 B134 B134 B136 B136 B136 B136 B137 B137
23 13 22 12 27 19 29 30 19 8 23 26 6
When secondary air is inducted: 3.2 4.9
Power supply GND (sensor) Secondary air combination valve relay 1 Secondary air combination valve relay 2 Secondary air pump relay Self-shutoff control Ground (ignition system)
EN(H4DOTC)(diag)-20

Connector No. B134 B137 B137 B137 B137 B136 Terminal No. 5 7 2 1 3 6 Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 0 0 0 0 0 0 0 0 0 0 0 Waveform
10ms 5V
Contents Ground (engine 1) Ground (engine 2) Ground (engine 3) Ground (engine 4) Ground (engine 5) Ground (body) Input/output name 1. Crankshaft position sensor
Note
Measuring condition At idling
ONE CRANK ROTATION
EN-05322
At idling
RH 0
ONE CAM ROTATION

LH 0
ONE CAM ROTATION
5V 50ms
EN-05359
EN(H4DOTC)(diag)-21

F/B FUSE No. 4 DATA LINK CONNECTOR
AT MT C25 MT CLUTCH SWITCH M/B FUSE No. 13 STARTER MOTOR IGNITION SWITCH CLUTCH START SWITCH B5 C16 B27 MT MT F/B FUSE No. 21 AT AT STARTER RELAY C20 TEST MODE CONNECTOR C6 C32 INHIBITOR RELAY MT NEUTRAL SWITCH JOINT CONNECTOR
1
B23
MT
MT TCM F/B FUSE No. 12 FUEL PUMP RELAY C12 M/B FUSE No. 11 FUEL PUMP CONTROL UNIT B33 B29 FUEL TEMPERATURE SENSOR B22 AT C31 B19 B21 B31
12
B30 B17
JOINT CONNECTOR
12 11 4 2 3
13
EN(H4DOTC)(diag)-22
ACCELERATOR PEDAL POSITION SENSOR
EN-06976

SBF-5 SBF-7
5
ELECTRONIC THROTTLE CONTROL RELAY C1
F/B FUSE No.7 F/B FUSE No.5 D18 IGNITION COIL No.1 D19
MAIN RELAY
C21
IGNITION COIL No.2
C23
D20
IGNITION COIL No.3
D21 D26 A7 B2 PURGE CONTROL SOLENOID VALVE 1 D29 A30 D6
IGNITION COIL No.4
PCV HOSE ASSY COMBINATION METER
C11 PURGE CONTROL SOLENOID VALVE 2 C7 BODY INTEGRATED UNIT (CAN COMMUNICATION)
MALFUNCTION INDICATOR LIGHT
I/F
MICRO COMPUTER
TACHOMETER
C22
I/F
SPEEDOMETER
A21 INTAKE CAMSHAFT POSITION SENSOR LH
A11 INTAKE CAMSHAFT POSITION SENSOR RH A22 POWER STEERING OIL PRESSURE SWITCH A33
EN-05715
EN(H4DOTC)(diag)-23

FUEL INJECTOR No. 1
D8
A18 D9
FUEL INJECTOR No. 2
A28 FUEL INJECTOR No. 3 D10
10
D4
D5 FUEL INJECTOR No. 4 D11 A19
WASTEGATE SOLENOID VALVE
D27
A6 A29
4
B18 B34 A34

B26 B35
EN-06126
EN(H4DOTC)(diag)-24

9 6
B9 FRONT OXYGEN (A/F) SENSOR RH B8 C2 C3 D12 D13 A16 B1
TUMBLE GENERATOR VALVE ASSY LH
B4 REAR OXYGEN SENSOR RH C4
D22 D23 A26
TUMBLE GENERATOR VALVE ASSY RH
D15
9
A27
D14
OIL FLOW CONTROL SOLENOID VALVE LH
SECONDARY AIR COMBINATION VALVE RH
D17 C30 D16
SECONDARY AIR COMBINATION VALVE RELAY 1
OIL FLOW CONTROL SOLENOID VALVE RH
C19 RELAY HOLDER FUSE 10A SECONDARY AIR COMBINATION VALVE RELAY 2 C8 RELAY HOLDER FUSE 60A SECONDARY AIR PUMP VALVE RELAY
SECONDARY AIR PUMP SECONDARY AIR COMBINATION VALVE LH
A13 A14 A24 CRANKSHAFT POSITION SENSOR
10
A15 A25 KNOCK SENSOR
10
EN-06950
EN(H4DOTC)(diag)-25

11 13 7
C24 A/C CONTROL MODULE
B32 C28 C33 A/C PRESSURE SWITCH
C9 C17 DRAIN VALVE A/C RELAY
STOP LIGHT SWITCH
B28
C26 C34 BODY INTEGRATED UNIT (IMMOBILIZER)
BRAKE SWITCH
B20 C27 C35 BODY INTEGRATED UNIT (CAN COMMUNICATION)
B12
D2 D1
10
D7 D3
SUB FAN RELAY
C18
C15
MT
MAIN FAN RELAY
C29
A5
ENGINE GROUND
EN-05718
EN(H4DOTC)(diag)-26


Contents Engine Load Specification 17.6 35.64 (%): Idling 13.2 26.73 (%): 2,500 rpm racing
Measuring condition: After engine is warmed up. Set the select lever in P range or N range, or the shift lever in neutral. Turn the A/C to OFF. Turn all the accessory switches to OFF.
EN(H4DOTC)(diag)-27
Data Link Connector


A: NOTE
9 10 11 12 13 14 15 16
EN-04893
Terminal No. 1 2 3 4 5 6 7 8
Contents Power supply Blank Blank Ground Ground CAN communication (+) Subaru Select Monitor signal Blank
Terminal No. 9 10 11 12 13 14 15 16
Contents Blank Blank Blank Blank Blank CAN communication () Blank Power supply
EN(H4DOTC)(diag)-28
General Scan Tool


A: OPERATION
EN-02533
3) Using the general scan tool, call up DTC and freeze frame data. General scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain DTC (4) MODE $04: Clear/Reset emission-related diagnostic information (5) MODE $06: Request on-board monitoring test results for intermittently monitored systems (6) MODE $07: Request on-board monitoring test results for continuously monitored systems (7) MODE $09: Request vehicle information Read out the data according to repair procedures. (For detailed operation procedure, refer to the general scan tool operation manual.) NOTE: For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-81, List of Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-29
General Scan Tool

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

PID $01 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $12 $13 $15 $1C $1F $21 $24 $2E $2F $30 $31 $32 $33 $34 $3C $41 $42 $43 $44 $45 $46 $47 $49 $4A $4C $4D $4E $51 $5A Data Number of emission-related powertrain DTC, and malfunction indicator light status and diagnosis support information Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Air flow rate from the mass air flow sensor Throttle valve absolute opening angle Secondary air control status Check whether oxygen sensor is installed. Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor Supporting OBD system Elapsed time after starting the engine Running distance after MIL turns on A/F value and A/F sensor output voltage Evaporative purge Fuel level Number of warm ups after DTC clear Travel distance after DTC clear Tank pressure Atmospheric pressure A/F sensor O value, current Catalyzer temperature Diagnosis monitoring per drive cycle ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Engine operation time during MIL on Elapsed time after DTC clear Fuel used Relative accelerator opening angle Unit of measure % C % % kPa rpm MPH C g/s % V and % sec miles and V % % miles Pa kPa and mA C V % % C % % % % min min %
EN(H4DOTC)(diag)-30
General Scan Tool


PID $02 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $12 $13 $15 $1C $1F $2E $2F $32 $33 $42 $43 $44 $45 $46 $47 $49 $4A $4C Data DTC that caused the freeze frame data storage required by CARB Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Air flow rate from the mass air flow sensor Throttle valve absolute opening angle Secondary air control status Air fuel ratio sensor Rear oxygen sensor voltage, compensation value Supporting OBD system Elapsed time after starting the engine Evaporative purge Fuel level Tank pressure Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Unit of measure % C % % kPa rpm MPH C gm/s % V and % sec % % Pa kPa V % % C % % % %
NOTE: Refer to general scan tool manufacturers operation manual to access freeze frame data (MODE $02).

Refer to List of Diagnostic Trouble Code (DTC) for information about data denoting emission-related powertrain DTC. <Ref. to EN(H4DOTC)(diag)-81, List of Diagnostic Trouble Code (DTC).>

EN(H4DOTC)(diag)-31
General Scan Tool

6. MODE $06
OBDMID TID $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $89 $93 $94 $95 $96 $97 $98 $99 $9A $9B $9C $9D $9E $9F $A0 $B0 $B1 $B1 $B2 $B2 $B3 $B4 $B5 $B6 $B7 $0B $0C $0B $0C $0B $0C $0B $0C $0B $0C $A6 SID $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $20 $FE $FE $FE $FE $FE $FE $24 $24 $14 $24 $24 $17 $0B $0B $17 $0B $17 $0B $17 $0B $0B $0B $31 $31 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $FE Diagnostic item A/F sensor conduction abnormal (Bank 1 Sensor 1)
$01
A/F sensor range failure (Bank 1 Sensor 1) A/F sensor response failure (Bank 1 Sensor 1) Oxygen sensor circuit abnormal (Bank 1 Sensor 2)
$02
Oxygen sensor drop failure (Bank 1 Sensor 2)
Oxygen sensor response failure (Bank 1 Sensor 2) Catalyst degradation diagnosis (B1) Evaporative emission control system leak detected (Fuel filler cap off) Evaporative emission control system (0.04 inch leak) Evaporative emission control system (0.02 inch leak) Evaporative emission control system (purge flow) A/F sensor heater failure (Bank 1 Sensor 1) A/F sensor heater characteristics failure (Bank 1 Sensor 1) Oxygen sensor heater abnormal (Bank 1 Sensor 2)
$21 $39 $3B $3C $3D $41
$42
Secondary air system (whole system)
$71
Secondary air system (relay 2 combination valve 2)
$A1 $A2 $A3 $A4 $A5 $E1
Misfire monitoring (All cylinders) Misfire monitoring (#1 cylinder) Misfire monitoring (#2 cylinder) Misfire monitoring (#3 cylinder) Misfire monitoring (#4 cylinder) Purge control solenoid valve 2 close seized
EN(H4DOTC)(diag)-32
General Scan Tool

7. MODE $07
8. MODE $09
Refer to the data of vehicle specification (V.I.N., calibration ID, etc.).
EN(H4DOTC)(diag)-33


A: OPERATION
1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4DOTC)(diag)-7, PREPARATION TOOL, General Description.>
EN-05692
EN-02533
EN(H4DOTC)(diag)-34


Contents Engine Load Engine coolant temperature signal A/F correction 1 A/F learning 1 Intake manifold absolute pressure Display Engine Load Coolant Temp. A/F Correction #1 A/F Learning #1 Mani. Absolute Pressure Unit of measure % C or F % % mmHg, kPa, inHg or psig Note (at idling) 21.0% 80 100C or 176 212F 10 +10% 15 +15% 220 275 mmHg, 29.5 37 kPa, 8.7 10 inHg or 4.2 5.3 psig 630 770 rpm (Agree with the tachometer indication) 0 km/h or 0 MPH (at parking) 10 15 deg 20 50C or 68 122F 2.1 3.1 g/s or 0.35 0.40 lb/m 2.0 2.4% 0 1.0 V 12 15 V 1.0 1.7 V 1.2 2.2 ms (Intake manifold absolute pressure atmospheric pressure) 0 deg 0.0% +28C or 82F 0.0% 0 25% 0.81 V 0.81 V 30 40% 5 deg 5 deg 0 20% 0 20% 40 100 mA 40 100 mA 20 20 mA
Engine speed signal Meter vehicle speed signal Ignition timing signal Intake air temperature signal Intake air amount Throttle opening angle signal Rear oxygen sensor voltage Battery voltage Mass air flow voltage Injection 1 pulse width Atmospheric pressure Intake manifold relative pressure Ignition timing learning value Acceleration opening angle signal Fuel temperature signal Primary supercharged pressure control signal Purge control solenoid duty ratio Tumble generator valve RH opening signal Tumble generator valve LH opening signal Fuel pump duty ratio AVCS advance angle amount RH AVCS advance angle amount LH Oil flow control solenoid valve duty RH (AVCS) Oil flow control solenoid valve duty LH (AVCS) Oil flow control solenoid valve current RH Oil flow control solenoid valve current LH A/F sensor current value 1
Engine Speed Vehicle Speed Ignition Timing Intake Air Temp. Mass Air Flow Throttle Opening Angle Rear O2 Sensor Battery Voltage Air Flow Sensor Voltage Fuel Injection #1 Pulse Atmosphere Pressure Mani. Relative Pressure Learned Ignition Timing Accel. Opening Angle Fuel Temp. Primary Control CPC Valve Duty Ratio TGV Position Sensor R TGV Position Sensor L Fuel Pump Duty VVT Adv. Ang. Amount R VVT Adv. Ang. Amount L OCV Duty R OCV Duty L OCV Current R OCV Current L A/F Sensor #1 Current
rpm km/h or MPH deg C or F g/s or lb/m % V V V ms mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig deg % C or F % % V V % deg deg % % mA mA mA
EN(H4DOTC)(diag)-35

Contents A/F sensor resistance value 1 A/F sensor output lambda 1 A/F correction 3 A/F learning 3 SI drive mode Throttle motor duty Throttle power supply voltage Sub throttle sensor voltage Main throttle sensor voltage Sub accelerator sensor voltage Main acceleration sensor voltage Secondary air supply piping pressure signal Secondary airflow signal Memory vehicle speed Fuel level sensor resistance Odd Meter #1 cylinder roughness monitor #2 cylinder roughness monitor #3 cylinder roughness monitor #4 cylinder roughness monitor Knock sensor correction Fuel tank pressure signal AT/MT identification terminal Delivery (test) mode terminal D check request flag Delivery (test) mode terminal Neutral position switch signal Soft idle switch signal Ignition switch signal Power steering switch signal Air conditioning switch signal Starter switch signal Rear oxygen monitor Knocking signal Crankshaft position sensor signal Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Light switch signal A/C middle pressure switch signal Air conditioner compressor relay output signal Radiator fan relay 1 signal Radiator fan relay 2 signal PCV hose assembly diagnosis signal Pressure control solenoid valve signal Tumble generator valve output signal Tumble generator valve driving signal Display A/F Sensor #1 Resistance A/F Sensor #1 A/F Correction #3 A/F Learning #3 SI Drive mode Throttle Motor Duty Throttle Motor Voltage Sub-Throttle Sensor Main-Throttle Sensor Sub-Accelerator Sensor Main-Accelerator Sensor Sec. Air Piping Pressure Sec. Air Flow Memorized Cruise Speed Fuel level resistance Odometer Roughness Monitor #1 Roughness Monitor #2 Roughness Monitor #3 Roughness Monitor #4 Knocking Correction Fuel Tank Pressure AT Vehicle ID Signal Test Mode Signal D-check Require Flag Delivery Mode Connector (Test Mode Connector) Neutral Position Switch Idle Switch Signal Ignition Switch P/S Switch Signal A/C Switch Starter Switch Rear O2 Rich Signal Knocking Signal Crankshaft Position Sig. Camshaft Position Sig. Rear Defogger SW Blower Fan SW Light Switch A/C Mid Pressure Switch A/C Compressor Signal Radiator Fan Relay #1 Radiator Fan Relay #2 Blow-by leak Connector PCV Solenoid Valve TGV Output TGV Drive Unit of measure : % % % V V V V V mmHg, kPa, inHg or psig g/s or lb/m km/h or MPH : km deg mmHg, kPa, inHg or psig Note (at idling) 27 35 mA 1.0 0.00% 0.00% I, S or S# 5% 12 15 V 1.5 V 0.6 V 1.1 V 1.0 V 765 mmHg, 102 kPa, 30.1 inHg or 14.8 psig 0.00 g/s or 0.00 lb/m 4 96 : 0 0 0 0 0.0 deg +8.8 mmHg, +1.2 kPa, +0.4 inHg or +0.2 psig AT vehicle/MT vehicle OFF OFF OFF ON ON ON OFF input (When OFF) OFF input (When OFF) OFF Rich/Lean None ON ON OFF input (When OFF) OFF input (When OFF) OFF input (When OFF) OFF input (When OFF) OFF output (when OFF) OFF output (when OFF) OFF output (when OFF) Connected OFF output (when OFF) None Opening direction
EN(H4DOTC)(diag)-36

Contents Drain valve signal Purge control solenoid valve 2 signal AT coordinate retard angle demand signal AT coordinate fuel cut demand signal Vehicle dynamics control (VDC) torque down prohibition output Vehicle dynamics control (VDC) torque down demand Torque control permission signal ETC motor relay signal Clutch switch signal Stop light switch signal SET/COAST switch signal RES/ACC switch signal Brake switch signal Main switch signal Body integrated unit data reception Body integrated unit counter update Secondary air combination valve relay 2 signal Secondary air pump relay signal Secondary air combination valve relay 1 signal Cruise control cancel switch signal Malfunction indicator light signal Display Vent. Solenoid Valve CPC Solenoid 2 Retard Signal from AT Fuel Cut signal from AT Ban of Torque Down Request Torque Down VDC Torque Permission Signal ETC Motor Relay Clutch Switch Stop Light Switch SET/COAST Switch RESUME/ACCEL Switch Brake Switch Main Switch Body Int. Unit Data Body Int. Unit Count Sec. Air Combi V Relay 2 Secondary Air Pump Relay Sec. Air Combi V Relay 1 CC Cancel SW MIL On Flag Unit of measure Note (at idling) OFF output (when OFF) OFF (when OFF) None None Permission None ON/OFF ON OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) ON ON OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) Off (when unlit)
EN(H4DOTC)(diag)-37


1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Current Data Display & Save}. 6) On the Current Data Display & Save display screen, select the {All data display}. 7) Using the scroll key, scroll the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Number of diagnosis code Condition of malfunction indicator light Monitoring test of misfire Monitoring test of misfire Monitoring test of fuel system Monitoring test of fuel system Monitoring test of comprehensive component Monitoring test of comprehensive component Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system Test of evaporative emission purge control system Secondary air system test Secondary air system test Test of air conditioning system refrigerant Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Intake manifold absolute pressure signal Display Number of Diag. Code: MI(MIL) Misfire monitoring (Supp) Misfire monitoring (Rdy) Fuel system monitoring (Supp) Fuel system monitoring (Rdy) Component monitoring (Supp) Component monitoring (Rdy) Catalyst Diagnosis (Supp) Catalyst Diagnosis (Rdy) Heated catalyst (Supp) Heated catalyst (Rdy) Evaporative purge system (Supp) Evaporative purge system (Rdy) Secondary air system (Supp) Secondary air system (Rdy) A/C system refrigerant (Supp) A/C system refrigerant (Rdy) Oxygen sensor (Supp) Oxygen sensor (Rdy) O2 Heater Diagnosis (Supp) O2 Heater Diagnosis (Rdy) EGR system (Supp) EGR system (Rdy) Fuel system for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Referential value (at idling) 0 OFF YES YES YES YES YES YES YES NO NO N/A YES NO YES NO NO N/A YES NO YES YES NO N/A Cl_normal 19.2 96 17.2 5.5 248 Unit of measure % C % % mmHg
EN(H4DOTC)(diag)-38

Contents Engine speed signal Vehicle speed signal #1 Cylinder ignition timing Intake air temperature signal Intake air amount Throttle position signal Secondary air control status Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (bank 1 sensor 1) Oxygen sensor (Bank 1 Sensor 2) Elapsed time after engine start Travel distance after the malfunction indicator light illuminates A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) Evaporative purge Fuel level signal Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure signal Atmospheric pressure signal A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) Catalytic temperature #1 Monitoring test of misfire Monitoring test of misfire Monitoring test of fuel system Monitoring test of fuel system Monitoring test of comprehensive component Monitoring test of comprehensive component Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system Test of evaporative emission purge control system Secondary air system test Secondary air system test Display Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Secondary air system Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start Lighted MI lamp history A/F Sensor #11 A/F Sensor #11 Commanded Evap Purge Fuel Level Number of warm-ups Meter since DTC cleared Fuel Tank Pressure Atmosphere Pressure A/F Sensor #11 A/F Sensor #11 Catalyst Temperature #11 Misfire monitoring (Enable) Misfire monitoring (Comp) Fuel system monitoring (Enable) Fuel system monitoring (Comp) Component monitoring (Enable) Component monitoring (Comp) Catalyst Diagnosis (Enable) Catalyst Diagnosis (Comp) Heated catalyst (Enable) Heated catalyst (Comp) Evaporative purge system (Enable) Evaporative purge system (Comp) Secondary air system (Enable) Secondary air system (Comp) Referential value (at idling) 846 0 13.5 44 3.6 13 Stop 0.1 0.7 0.0 OBD/OBD2 Support Support 0.951 2.468 0 9.664 Atmospheric pressure 0.957 0.18 YES YES YES NO NO NO YES NO N/A N/A YES NO YES NO Unit of measure rpm km/h C g/s % V % sec km V % % km mmHg mmHg mA C
EN(H4DOTC)(diag)-39

Contents Test of air conditioning system refrigerant Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light lit Elapsed time after DTC clear Fuel used Relative accelerator opening angle Display A/C system refrigerant (Enable) A/C system refrigerant (Comp) Oxygen sensor (Enable) Oxygen sensor (Comp) O2 Heater Diagnosis (Enable) O2 Heater Diagnosis (Comp) EGR system (Enable) EGR system (Comp) Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. Time while MIL lighted Time since DTC cleared Type of fuel Relative Accelera. Pos. Referential value (at idling) N/A N/A YES NO YES YES N/A N/A 13.848 21 0.993 2 Ambient temperature 31 13 13 0 GAS 0 Unit of measure V % % C % % % % min min %
EN(H4DOTC)(diag)-40


Contents DTC of freeze frame data Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing adv. #1 Intake air temperature Amount of intake air Throttle opening angle Secondary air control status Oxygen sensor #12 A/F correction #12 OBD system Oxygen sensor #11 Oxygen sensor #12 Elapsed time after starting the engine Evaporative purge Fuel level Tank pressure Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Display Freeze frame data Fuel system for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Secondary air system Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start Commanded Evap Purge Fuel Level Fuel Tank Pressure Atmosphere Pressure Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. Unit of measure DTC % C or F % % mmHg, kPa, inHg or psi rpm km/h or MPH C g/s % V % Support Support sec % % mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig V % % C or F % % % %
5. V.I.N. REGISTRATION
EN(H4DOTC)(diag)-41


A: OPERATION
1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display}. 5) On the Diagnostic Code(s) Display display, select the {Temporary Diagnostic Code(s)} or {Memorized Diagnostic Code(s)}. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-81, List of Diagnostic Trouble Code (DTC).>

Refer to data denoting emission-related powertrain DTC. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-81, List of Diagnostic Trouble Code (DTC).> NOTE: Refer to general scan tool manufacturers instruction manual to access powertrain DTC (MODE $03).

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Diagnostic Code(s) Display}. 6) Make sure DTC is shown on the screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-81, List of Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-42
Inspection Mode
11.Inspection Mode
A: PROCEDURE
Perform the diagnosis shown in the following DTC table. When performing the diagnosis not listed in List of Diagnostic Trouble Code (DTC), refer to the item on the drive cycle. <Ref. to EN(H4DOTC)(diag)-48, Drive Cycle.>
DTC P0011 P0016 P0018 P0021 P0031 P0032 P0037 P0038 P0102 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0137 P0138 P0140 P0182 P0183 P0222 P0223 P0230 P0245 P0327 P0328 P0335 P0336 P0340 P0345 P0413 P0416 P0418 P0447 P0448 P0452 P0453 P0458 P0462 Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank1) Crankshaft Position - Camshaft Position Correlation (Bank2) Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch A Circuit Low Throttle/Pedal Position Sensor/Switch A Circuit High O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) Fuel Temperature Sensor A Circuit Low Input Fuel Temperature Sensor A Circuit High Input Throttle/Pedal Position Sensor/Switch B Circuit Low Throttle/Pedal Position Sensor/Switch B Circuit High Fuel Pump Primary Circuit Turbo/Super Charger Wastegate Solenoid A Low Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) Crankshaft Position Sensor A Circuit Crankshaft Position Sensor A Circuit Range/Performance Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor) Camshaft Position Sensor A Circuit (Bank 2) Secondary Air Injection System Switching Valve A Circuit Open Secondary Air Injection System Switching Valve B Circuit Secondary Air Injection System Control A Circuit Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission System Purge Control Valve Circuit Low Fuel Level Sensor A Circuit Low Condition
EN(H4DOTC)(diag)-43
Inspection Mode
DTC P0463 P0500 P0512 P0513 P0600 P0604 P0605 P0607 P0638 P0700 P0851 P0852 P1152 P1153 P1160 P1400 P1410 P1420 P1491 P1560 P1570 P1571 P1572 P1574 P1576 P1577 P1578 P2006 P2007 P2008 P2009 P2011 P2012 P2016 P2017 P2021 P2022 P2088 P2089 P2092 P2093 P2101 P2102 P2109 P2122 P2123 P2127 P2128 P2135 P2138 Item Fuel Level Sensor A Circuit High Vehicle Speed Sensor A Starter Request Circuit Incorrect Immobilizer Key Serial Communication Link Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (MIL Request) Park/Neutral Switch Input Circuit Low Park/Neutral Switch Input Circuit High O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Fuel Tank Pressure Control Solenoid Valve Circuit Low Secondary Air Injection System Switching Valve Stuck Open Fuel Tank Pressure Control Sol. Valve Circuit High Positive Crankcase Ventilation (Blow-By) Function Problem Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Intake Manifold Runner Control Stuck Closed (Bank 1) Intake Manifold Runner Control Stuck Closed (Bank 2) Intake Manifold Runner Control Circuit / Open (Bank 1) Intake Manifold Runner Control Circuit Low (Bank 1) Intake Manifold Runner Control Circuit / Open (Bank 2) Intake Manifold Runner Control Circuit Low (Bank 2) Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 2) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 2) Intake Camshaft Position Actuator Control Circuit Low (Bank 1) Intake Camshaft Position Actuator Control Circuit High (Bank 1) Intake Camshaft Position Actuator Control Circuit Low (Bank 2) Intake Camshaft Position Actuator Control Circuit High (Bank 2) Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle/Pedal Position Sensor A Minimum Stop Performance Throttle/Pedal Position Sensor/Switch D Circuit Low Input Throttle/Pedal Position Sensor/Switch D Circuit High Input Throttle/Pedal Position Sensor/Switch E Circuit Low Input Throttle/Pedal Position Sensor/Switch E Circuit High Input Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation Condition
EN(H4DOTC)(diag)-44
Inspection Mode
DTC P2419 P2420 P2431 P2432 P2433 P2444 Item Evaporative Emission System Switching Valve Control Circuit Low Evaporative Emission System Switching Valve Control Circuit High Secondary Air Injection System Air Flow /Pressure Sensor Circuit Range/Performance Secondary Air Injection System Air Flow /Pressure Sensor Circuit Low Secondary Air Injection System Air Flow /Pressure Sensor Circuit High Secondary Air Injection System Pump Stuck On Condition

1) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)]. 2) Lift up the vehicle using a garage jack and place it on rigid racks, or drive the vehicle onto free rollers. WARNING: Before lifting up the vehicle, ensure parking brakes are applied. Do not use a pantograph jack in place of a rigid rack. Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front wheels. Before rotating the wheels, make sure that there is no one in front of the vehicle. Besides while the wheels are rotating, make sure that no one approaches the vehicle front side. Make sure that there is nothing around the wheels. For AWD model, pay special attention to all four wheels. While servicing, do not depress or release the clutch pedal or accelerator pedal quickly regardless of the engine speed. Quick operation may cause the vehicle to drop off the free roller. To prevent the vehicle from slipping due to vibration, do not place anything between rigid rack and the vehicle.
(A)
(B)
EN-00041
EN(H4DOTC)(diag)-45
Inspection Mode

1) Check that no DTC remains after clearing memory. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 2) Warm up the engine. 3) Prepare the Subaru Select Monitor kit. <Ref. to EN(H4DOTC)(diag)-7, PREPARATION TOOL, General Description.>
EN-02533
EN-05692
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 9) Start the PC. 10) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 11) On the Main Menu display screen, select the {Each System Check}. 12) On the System Selection Menu display screen, select the {Engine Control System}. 13) Click the [OK] button after the information of engine type has been displayed. 14) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure}. 15) When the Perform Inspection (Dealer Check) Mode? is shown on the screen, click the [Next] button. 16) Perform subsequent procedures as instructed on the display screen. If trouble still remains in the memory, the corresponding DTC appears on the display screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-81, List of Diagnostic Trouble Code (DTC).> Release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this does not indicate a malfunction. When engine control diagnosis is finished, perform the ABS memory clearance procedure of the self-diagnosis system. <Ref. to ABS(diag)-20, Clear Memory Mode.>
(A)
PI-00201
EN(H4DOTC)(diag)-46
Inspection Mode

1) Check that no DTC remains after clearing memory. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 2) Warm up the engine. 3) Connect the delivery (test) mode connector (A) located under the glove box.
9) Place the select lever or shift lever in D position (AT model) or 1st gear (MT model) and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: For AWD model, release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system. <Ref. to ABS(diag)-20, Clear Memory Mode.> 10) Using the general scan tool, check DTC and record the result(s). NOTE: For detailed operation procedures, refer to the general scan tool operation manual. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag)-81, List of Diagnostic Trouble Code (DTC).>
(A)
PI-00201
EN-02533
5) Start the engine. NOTE: Make sure the select lever is placed in the P position before starting. (AT model) Depress the clutch pedal when starting engine. (MT model) 6) Turn the neutral position switch to ON using select lever or shift lever. 7) Depress the brake pedal to turn the brake switch ON. (AT model) 8) Keep the engine speed in 2,500 3,000 rpm range for 40 seconds.
EN(H4DOTC)(diag)-47
Drive Cycle
12.Drive Cycle
A: PROCEDURE

1) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)]. 2) After performing the diagnostics and clearing the memory, check that no DTC remains. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 3) Disconnect the delivery (test) mode connector. NOTE: Except for the water temperature specified at starting, be sure to carry out the diagnosis after the engine is warmed up. Perform the diagnosis twice if the DTC marked with *. After completing the first diagnosis, stop the engine and perform second diagnosis in same condition.
2. DRIVE CYCLE A DRIVE THE VEHICLE WITH 80 KM/H (50 MPH) FOR 20 MINUTES, AND THEN IDLE THE ENGINE FOR A MINUTE)
DTC *P0125 *P0126 *P0128 *P0133 *P0171 *P0172 *P0301 *P0302 *P0303 *P0304 *P0420 *P0441 *P0442 *P0451 *P0456 *P0457 *P0459 P1443 *P2096 *P2097 P2103 Condition Engine coolant temperature at engine start is less Insufficient Coolant Temperature for Closed Loop Fuel Control than 20C (68F). Insufficient Engine Coolant Temperature For Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Ther- Engine coolant temperature at engine start is less mostat Regulating Temperature) than 55C (131F). O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) System Too Lean (Bank 1) Complete diagnosis with drive cycle B or C as well. System Too Rich (Bank 2) Complete diagnosis with drive cycle B or C as well. Cylinder 1 Misfire Detected Complete diagnosis with drive cycle B or C as well. Cylinder 2 Misfire Detected Complete diagnosis with drive cycle B or C as well. Cylinder 3 Misfire Detected Complete diagnosis with drive cycle B or C as well. Cylinder 4 Misfire Detected Complete diagnosis with drive cycle B or C as well. Catalyst System Efficiency below Threshold (Bank 1) Evaporative Emission Cont. System Incorrect Purge Flow Evaporative Emission Control System Leak Detected Engine coolant temperature at engine start is less (Small Leak) than 25C (77F). Evaporative Emission Control System Pressure Sensor Evaporative Emission Control System Leak Detected Engine coolant temperature at engine start is less (Very Small Leak) than 25C (77F). Evaporative Emission Control System Leak Detected Engine coolant temperature at engine start is less (Fuel Cap Loose/Off) than 25C (77F). Evaporative Emission System Purge Control Valve Circuit High Vent Control Solenoid Valve Function Problem Post Catalyst Fuel Trim System Too Lean (Bank 1) Complete diagnosis with drive cycle B or C as well. Post Catalyst Fuel Trim System Too Rich (Bank 1) Complete diagnosis with drive cycle B or C as well. Throttle Actuator Control Motor Circuit High Complete diagnosis with drive cycle B or C as well. Item
EN(H4DOTC)(diag)-48
Drive Cycle

NOTE: Drive the vehicle at 10 km/h (6 MPH) or faster before diagnosis.
DTC *P0171 *P0172 *P0301 *P0302 *P0303 *P0304 *P0464 *P0506 *P0507 *P2096 *P2097 P2103 Item System Too Lean (Bank 1) System Too Rich (Bank 2) Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Fuel Level Sensor Circuit Intermittent Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Throttle Actuator Control Motor Circuit High Condition Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well.

(H)
(C) 97 (60) (D) 64 (40) (F) (G)
(B)
(E)
(A) 0 50 100 150 (I) EN-00842
(A) (B) (C)
Idle the engine for 10 seconds or more. Accelerate the vehicle to 97 km/h (60 MPH) within 20 seconds. Drive the vehicle at 97 km/h (60 MPH) for 20 seconds.
(D) (E) (F)
Decelerate the vehicle to 64 km/h (40 MPH) with throttle fully closed. Drive the vehicle at 64 km/h (40 MPH) for 20 seconds. Accelerate the vehicle to 97 km/h (60 MPH) within 10 seconds.
(G) (H) (I)
Stop the vehicle with throttle fully closed. Vehicle speed km/h (MPH) Sec.
EN(H4DOTC)(diag)-49
Drive Cycle
DTC *P0030 *P0068 *P0101 P0134 *P0139 *P0171 *P0172 P0244 P0246 *P0301 *P0302 *P0303 *P0304 P2004 P2005 *P2096 *P2097 P2103 Item HO2S Heater Control Circuit (Bank 1 Sensor 1) MAP/MAF - Throttle Position Correlation Mass or Volume Air Flow Circuit Range/Performance O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) System Too Lean (Bank 1) System Too Rich (Bank 2) Turbo/Super Charger Wastegate Solenoid A Range/Performance Turbo/Super Charger Wastegate Solenoid A High Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Intake Manifold Runner Control Stuck Open (Bank 1) Intake Manifold Runner Control Stuck Open (Bank 2) Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Throttle Actuator Control Motor Circuit High Condition Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well.
5. DRIVE CYCLE D
DRIFT DIAGNOSIS 1) Make sure that the engine coolant temperature at engine starting is less than 30C (86F). 2) Make sure that fuel remains 10 2 (2.6 US gal, 2.2 Imp gal) or more and the battery voltage is 10.9 V or more. 3) Start the engine, and check that the engine coolant temperature increases by 10C (18F) or more, and reaches 75C (167F) or more, when the engine is warmed up. 4) After the engine has reached the state of procedure 3), idle the engine for 120 seconds or more. STUCK DIAGNOSIS 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 3) Drive for approximately 50 2 (13.2 US gal, 11 Imp gal) of fuel. NOTE: It is acceptable to drive the vehicle intermittently. Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
6. DRIVE CYCLE E
1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 3) Drive for approximately 30 2 (7.9 US gal, 6.6 Imp gal) of fuel. NOTE: It is acceptable to drive the vehicle intermittently. Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
EN(H4DOTC)(diag)-50
Drive Cycle
7. DRIVE CYCLE F
1) Make sure that the engine coolant temperature at engine starting is less than 30C (86F). 2) Start the engine, and warm it up until engine coolant temperature increases over 95C (203F). 3) Idle the engine for more than 10 minutes in the condition of step 2. NOTE: Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
DTC *P0111 Item Intake Air Temperature Sensor 1 Circuit Range/Performance Condition
8. DRIVE CYCLE G
1) Disconnect the battery negative terminal, and reconnect after 10 seconds has passed. 2) Start the engine and warm up engine until coolant temperature is 80C (176F). 3) Turn OFF the engine and wait until the coolant temperature drop to 40C (104F) or less. NOTE: Do not let engine coolant temperature drop to 5C (41F) or less. 4) Start the engine and warm up engine until coolant temperature is 80C (176F). 5) Turn OFF the engine and wait until the coolant temperature drop to 40C (104F) or less. NOTE: Do not let engine coolant temperature drop to 5C (41F) or less. 6) Start and idle the engine.
DTC
*P0410 *P0411
Item Secondary Air Injection System Secondary Air Injection System Incorrect Flow Detected Secondary Air Injection System Switching Valve A Circuit Shorted Secondary Air Injection System Switching Valve B Circuit Shorted Secondary Air Injection System Control A Circuit Shorted Secondary Air Injection System Switching Valve Stuck Open (Bank 1) Secondary Air Injection System Switching Valve Stuck Closed (Bank 1) Secondary Air Injection System Switching Valve Stuck Open (Bank2) Secondary Air Injection System Switching Valve Stuck Closed (Bank2)
Condition
P0414 P0417 P1418 *P2440 *P2441 *P2442 *P2443
9. DRIVE CYCLE H
1) Perform the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 2) With the ignition switch ON, read the engine coolant temperature, intake air temperature and fuel temperature. <Ref. to EN(H4DOTC)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> 3) If the values from step 2) satisfy the following two conditions, start the engine. Condition: |Engine coolant temperature intake air temperature | d 5C (41F) |Engine coolant temperature fuel temperature | d 2C (36F) NOTE: If the conditions are not satisfied, turn the ignition switch to OFF and wait until the parameters are satisfied. Start AT vehicles in the P range, and MT vehicles in the neutral position. 4) Idle the engine for 1 minute under the conditions in step 3).
DTC
*P1602
Condition
EN(H4DOTC)(diag)-51
Clear Memory Mode


A: OPERATION

For procedures clearing memory using the general scan tool, refer to the general scan tool operation manual. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. For this reason, start the engine after 10 seconds or more have elapsed since the ignition switch was turned to ON.


1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Clear Diagnostic Code}. 6) When the Clear Diagnostic Code? is shown on the screen, click the [Yes] button. 7) When Done and Turn off the ignition switch. is shown on the display screen, turn the ignition switch to OFF. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine. For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4DOTC)(diag)-52


A: OPERATION
EN-02533
EN-05692
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 7) Start the PC. 8) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 9) On the Main Menu display screen, select the {Each System Check}. 10) On the System Selection Menu display screen, select the {Engine Control System}. 11) Click the [OK] button after the information of engine type has been displayed. 12) On the Engine Diagnosis display screen, select the {System Operation Check Mode}. 13) On the System Operation Check Mode display screen, select the {Actuator ON/OFF Dr.}. 14) Select the desired compulsory actuator on the Actuator ON/OFF Operation display screen and click the [Next] button.
(A)
PI-00201
EN(H4DOTC)(diag)-53

15) Clicking the [Finished] button completes the compulsory valve operation check mode. The display will then return to the Actuator ON/OFF Operation screen. A list of the support data is shown in the following table.
Description Compulsory fuel pump relay operation check Compulsory purge control solenoid valve operation check Compulsory purge control solenoid valve 2 operation check Compulsory radiator fan relay operation check Compulsory air conditioning relay operation check Compulsory wastegate control solenoid valve operation check Compulsory pressure control solenoid valve operation check Compulsory drain valve operation check Compulsory secondary air combination valve 1 operation check Compulsory secondary air combination valve 2 operation check Compulsory secondary air pump relay operation check Display Fuel Pump Relay CPC Solenoid Valve CPC Solenoid 2 Radiator Fan Relay A/C Compressor Relay Turbocharger Wastegate Solenoid PCV Solenoid Valve Vent. Solenoid Valve Secondary Air Combi Valve 1 Secondary Air Combi Valve 2 Secondary Air Pump Relay

Display EGR Solenoid Valve ASV Solenoid Valve FICD Solenoid Pressure Switching Sol.1 Pressure Switching Sol.2 AAI Solenoid Valve Tank Sensor Cntl Valve EXH. Bypass Control Permit Flag
EN(H4DOTC)(diag)-54


A: OPERATION
12) The following items are displayed on the monitor.

Display Actuator ON/OFF Operation Immobilizer System Fuel Pump Control Fixed Idle Ignition Timing Idle Speed Control Injector Control
1. FUEL PUMP CONTROL (OFF DRIVE)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fuel Pump Control}. 2) On the Fuel Pump Control display screen, select the {OFF Operation}. 3) On the Start the Engine display screen, start the engine and click the [OK] button. 4) On the OFF Drive display screen, click the [Execution] button and execute the OFF drive. 5) Click the [Cancel] button to stop the OFF drive. 6) Click the [ Exit] button to end the OFF drive. The screen will return to the Fuel Pump Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN-05692
2. FUEL PUMP CONTROL (ON/OFF DRIVE)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fuel Pump Control}. 2) On the Fuel Pump Control display screen, select the {ON/OFF Dr.}. 3) On the Turn Ignition Switch ON with Engine OFF display screen, turn the ignition switch to ON and click the [OK] button. 4) On the ON/OFF Dr. display screen, click the [Execution] button and execute the ON/OFF drive. 5) Click the [Cancel] button to stop the ON/OFF drive. 6) Click the [ Exit] button to end the ON/OFF drive. The screen will return to the Fuel Pump Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN-02533
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 8) On the Main Menu display screen, select the {Each System Check}. 9) On the System Selection Menu display screen, select the {Engine Control System}. 10) Click the [OK] button after the information of engine type has been displayed. 11) On the Engine Diagnosis display screen, select the {System Operation Check Mode}.
EN(H4DOTC)(diag)-55


CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fixed Idle Ignition Timing}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) On the Fixed Idle Ignition Timing display screen, click the [Execution] button and execute the idling ignition timing fixed. 4) Click the [Cancel] button to stop the idling ignition timing fixed. 5) Click the [ Exit] button to end the idling ignition timing fixed. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
5. INJECTOR CONTROL. (INJECTION STOP MODE)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Injector Control}. 2) On the Injector Control display screen, select the {Injection Stop Mode}. 3) On the Injection Stop Mode display screen, select the fuel injector to be stopped. 4) On the Start the Engine display screen, start the engine and click the [OK] button. 5) On the Fuel Injector # display screen, click the [Execution] button and execute the injection stop mode. 6) Click the [Cancel] button to stop the injection stop mode. 7) Click the [ Exit] button to return the Injection Stop Mode display screen. 8) On the Injection Stop Mode display screen, click the [Return] button to end the Injection Stop Mode. The screen will return to the Injector Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Idle Speed Control}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) In the Idle Speed Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in a range between 500 rpm 2,000 rpm, in increments of 50 rpm. However, the engine speed that can actually be controlled will vary depending on the vehicle. 4) Click the [Cancel] button to stop the idle speed control. 5) Click the [ Exit] button to end the idle speed control. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
6. INJECTOR CONTROL. (INJECTION QUANTITY CONTROL)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Injector Control}. 2) On the Injector Control display screen, select the {Injection Quantity Control}. 3) On the Start the Engine display screen, start the engine and click the [OK] button. 4) In the Injection Quantity Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in a range between 0 20%, in increments of 1%. 5) Click the [Cancel] button to stop the injection quantity control. 6) Click the [ Exit] button to end the injection quantity control. The screen will return to the Injector Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H4DOTC)(diag)-56


A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4DOTC)(diag)-58, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> p 2. Malfunction indicator light does not come on. <Ref. to EN(H4DOTC)(diag)-59, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.> p 3. Malfunction indicator light does not go off. <Ref. to EN(H4DOTC)(diag)-61, MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF, Malfunction Indicator Light.> p 4. Malfunction indicator light does not blink. <Ref. to EN(H4DOTC)(diag)-62, MALFUNCTION INDICATOR LIGHT DOES NOT BLINK, Malfunction Indicator Light.> p 5. Malfunction indicator light remains blinking. <Ref. to EN(H4DOTC)(diag)-64, MALFUNCTION INDICATOR LIGHT REMAINS BLINKING, Malfunction Indicator Light.>
EN(H4DOTC)(diag)-57


1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit. <Ref. to EN(H4DOTC)(diag)-59, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>
(1) (2) (4)
(3)
EN-01681 (A) EN-05079
(1) (3) (4) (2) (3) (4) (5) (6) EN-01679
(1) (2) (3) (4)
(1) No DTC (2) Trouble occurs (3) ON (4) OFF (5) Ignition switch ON (6) Engine start
EN(H4DOTC)(diag)-58


B72 No.5 1
BATTERY
E
3 16
COMBINATION METER i10 i3 8 B38 11 ECM B136
i10 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
B72
B38
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05122
EN(H4DOTC)(diag)-59

Step Check Yes CHECK OUTPUT SIGNAL OF ECM. Is the voltage 10 V or more? Go to step 5. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 11 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 3. COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the combination meter. <Ref. to IDI-22, Combination Meter.> 3) Disconnect the connector from the ECM and combination meter. 4) Measure the resistance of harness between ECM and combination meter connector. Connector & terminal (B136) No. 11 (i10) No. 16: Is there poor contact in combi- Repair the poor nation meter connector? contact of combination meter connector. CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more? Replace the comTION METER AND IGNITION SWITCH CONbination meter NECTOR. board. <Ref. to IDI1) Turn the ignition switch to ON. 22, Combination 2) Measure the voltage between combination Meter.> meter connector and chassis ground. Connector & terminal (i10) No. 3 (+) Chassis ground (): CHECK POOR CONTACT. Check for poor contact of combination meter connector. No Go to step 2.
CHECK POOR CONTACT. Check for poor connection by shaking or pulling ECM connector and harness. CHECK ECM CONNECTOR. Check the connection of ECM connector.
Does the malfunction indicator Repair the poor light illuminate? contact of ECM connector. Is the ECM connector correctly Replace the ECM. Repair the connecconnected? <Ref. to tion of ECM conFU(H4DOTC)-52, nector. Engine Control Module (ECM).>
EN(H4DOTC)(diag)-60


B72 No.5 1
BATTERY
E
3 16
COMBINATION METER i10 i3 8 B38 11 ECM B136
i10 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
B72
B38
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05122
Step CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Turn the ignition switch to ON.
Check Yes Does the malfunction indicator Repair the short light illuminate? circuit of harness between ECM and combination meter connector.
No Replace the ECM. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).>
EN(H4DOTC)(diag)-61


E
3 16
COMBINATION METER i10 i3 8 B38
*
DELIVERY (TEST) MODE CONNECTOR 1 B75 1 B76
* *
B122
C11
B27
B: B135
C: B136
ECM
C6
B75
B76
B72
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2
1 2
1 2 3 4 5 6
i10 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
B38
B122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8
EN-05664
EN(H4DOTC)(diag)-62

Step Check Yes CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 2. CATOR LIGHT. light illuminate? 1) Turn the ignition switch to OFF. 2) Disconnect the delivery (test) mode connector. 3) Turn the ignition switch to ON. (engine OFF) No Repair the malfunction indicator light circuit. <Ref. to EN(H4DOTC)(diag) -59, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.> Does the malfunction indicator Repair the ground Go to step 3. CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. light illuminate? short circuit of har1) Turn the ignition switch to OFF. ness between 2) Disconnect the connectors from ECM. ECM and combi3) Turn the ignition switch to ON. nation meter connector. CHECK HARNESS BETWEEN ECM AND DE- Is the resistance less than 1 :? Go to step 4. Repair the harness LIVERY (TEST) MODE CONNECTOR. and connector. 1) Turn the ignition switch to OFF. NOTE: 2) Disconnect the connectors from ECM. In this case, repair 3) Measure the resistance of harness between the following item: ECM and delivery (test) mode connector. Open circuit of Connector & terminal harness between (B76) No. 1 (B136) No. 6: ECM and delivery (B75) No. 1 (B135) No. 27: (test) mode connector Poor contact in joint connector CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the ECM. Check for poor contact of the ECM connector. connector? contact of ECM <Ref. to connector. FU(H4DOTC)-52, Engine Control Module (ECM).>
EN(H4DOTC)(diag)-63


E
3 16
COMBINATION METER i10 i3 8 B38
*
DELIVERY (TEST) MODE CONNECTOR 1 B75 1 B76
* *
B122
C11
B27
B: B135
C: B136
ECM
C6
B75
B76
B72
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2
1 2
1 2 3 4 5 6
i10 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
B38
B122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8
EN-05664
EN(H4DOTC)(diag)-64

Step Check Yes CHECK DELIVERY (TEST) MODE CONNEC- Does the malfunction indicator Go to step 2. TOR. light blink? 1) Disconnect the delivery (test) mode connector. 2) Turn the ignition switch to ON. No System is normal. NOTE: Malfunction indicator light blinks when delivery (test) mode connector is connected. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? Repair the short Replace the ECM. CHASSIS GROUND TERMINAL. circuit of harness <Ref. to 1) Turn the ignition switch to OFF. between ECM and FU(H4DOTC)-52, 2) Disconnect the connectors from ECM. Engine Control delivery (test) 3) Measure the resistance of harness between mode connector. Module (ECM).> ECM and chassis ground. Connector & terminal (B135) No. 27 Chassis ground:
EN(H4DOTC)(diag)-65


A: PROCEDURE
1. Check of the fuel amount p 2. Inspection of starter motor circuit. <Ref. to EN(H4DOTC)(diag)-67, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> p 3. Inspection of ECM power supply and ground line. <Ref. to EN(H4DOTC)(diag)-71, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> p 4. Inspection of ignition control system. <Ref. to EN(H4DOTC)(diag)-73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> p 5. Inspection of fuel pump circuit. <Ref. to EN(H4DOTC)(diag)-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.> p 6. Inspection of fuel injector circuit. <Ref. to EN(H4DOTC)(diag)-77, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(H4DOTC)(diag)-66


CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
IGNITION SWITCH B72 BATTERY SBF-6 3 2 No. 21 MAIN SBF
MT AT
E
11 15 CLUTCH START SWITCH B106 10 2 7 13 9 1
INHIBITOR RELAY B226
STARTER RELAY B225 16 14
STARTER MOTOR
AT
MT B14
31
11
TCM B55
ECM B136
B106 1 2 B226 1 2 3 4 7 8 9 10 11 5 6
32
20
B72 1 2 3 4 5 6 B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28
B225 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
EN-06951
EN(H4DOTC)(diag)-67

Step Check CHECK BATTERY. Is the voltage 12 V or more? Check the battery voltage. CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate? CHECK DTC. Is DTC displayed? <Ref. to EN(H4DOTC)(diag)-42, OPERATION, Read Diagnostic Trouble Code (DTC).> Yes Go to step 2. Go to step 3. Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> No Charge or replace the battery. Go to step 4. The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 5.
1 2 3
CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage 10 V or more? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from starter motor. 3) On AT models, set the select lever to the P range or N range, and on MT models, depress the clutch pedal. 4) Turn the ignition switch to START. 5) Measure the voltage between the starter motor connector and the engine ground. Connector & terminal (B14) No. 1 (+) Engine ground (): CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage 10 V or more? TOR. 1) On AT models, set the select lever to the P range or N range, and on MT models, depress the clutch pedal. 2) Turn the ignition switch to START. 3) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B225) No. 14 (+) Chassis ground (): CHECK HARNESS BETWEEN BATTERY Is the voltage 10 V or more? AND IGNITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition switch. 3) Measure the voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 3 (+) Chassis ground ():
Repair the open circuit of the harness between starter relay connector and starter motor.
Go to step 6.
Go to step 7.
Is the resistance less than 1 :? Go to step 8. CHECK IGNITION SWITCH. Measure the resistance between ignition switch terminals after turning the ignition switch to START position. Terminals No. 2 No. 3:
EN(H4DOTC)(diag)-68

Step CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Remove the starter relay. 2) Connect the connector to ignition switch. 3) Turn the ignition switch to START. 4) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B225) No. 13 (+) Chassis ground (): CHECK STARTER RELAY. 1) Connect the battery to starter relay terminals No. 15 and No. 16. 2) Measure the resistance between starter relay terminals. Terminals No. 13 No. 14: CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and starter relay connector. Connector & terminal (B136) No. 20 (B225) No. 16: CHECK TRANSMISSION TYPE. CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Depress the clutch pedal. 2) Turn the ignition switch to START. 3) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B225) No. 15 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND CLUTCH START SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the clutch start switch connector. 3) Measure the resistance of harness between ECM and clutch start switch connector. Connector & terminal (B136) No. 32 (B106) No. 2: Check Is the voltage 10 V or more? Yes Go to step 9. No Repair the open circuit of harness between starter relay connector and ignition switch connector.
Replace the starter relay.
10
11 12
Is the transmission type AT? Is the voltage 10 V or more?
13
14
CHECK INPUT VOLTAGE OF CLUTCH START SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the clutch start switch connector. 3) Turn the ignition switch to START. 4) Measure the voltage between the clutch start switch connector and chassis ground. Connector & terminal (B106) No. 1 (+) Chassis ground ():
Is the resistance less than 1 :? Check the ECM power supply and ground line. <Ref. to EN(H4DOTC)(diag) -71, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> Is the voltage 10 V or more? Go to step 15.
Repair the open circuit of harness between ECM and clutch start switch connector.
Check the following item and repair if necessary. Blown out of fuse Open or ground short circuit of harness between ignition switch connector and clutch start switch connector
EN(H4DOTC)(diag)-69

Step Check CHECK CLUTCH START SWITCH. Is the resistance less than 1 :? Measure the resistance between clutch start switch terminals while depressing the clutch pedal. Terminals No. 1 No. 2: CHECK INPUT VOLTAGE OF STARTER RE- Is the voltage 10 V or more? LAY. 1) Connect the connector to ECM. 2) Place the select lever in P range or N range. 3) Turn the ignition switch to START. 4) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B225) No. 15 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 :? HIBITOR RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the inhibitor relay connector. 3) Measure the resistance of harness between ECM and inhibitor relay connector. Connector & terminal (B136) No. 31 (B226) No. 7: (B136) No. 32 (B226) No. 10: Yes Repair the open circuit of harness between clutch start switch connector and starter relay connector. Go to step 17. No Replace the clutch start switch. <Ref. to CL-37, Clutch Switch.>
15
16
Go to step 18.
17
18
CHECK INPUT VOLTAGE OF INHIBITOR RE- Is the voltage 10 V or more? LAY. 1) Turn the ignition switch to OFF. 2) Disconnect the inhibitor relay connector. 3) Turn the ignition switch to START. 4) Measure the voltage between inhibitor relay connector and chassis ground. Connector & terminal (B226) No. 9 (+) Chassis ground (): (B226) No. 11 (+) Chassis ground (): CHECK INHIBITOR RELAY. Is the resistance less than 1 :? 1) Connect the battery to inhibitor relay terminals No. 7 and No. 9. 2) Measure the resistance between inhibitor relay terminals. Terminals No. 10 No. 11: CHECK HARNESS BETWEEN INHIBITOR Is the resistance less than 1 :? RELAY CONNECTOR AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between inhibitor relay connector and starter relay connector. Connector & terminal (B226) No. 10 (B225) No. 15:
Check the ECM power supply and ground line. <Ref. to EN(H4DOTC)(diag) -71, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> Go to step 19.
Repair the open circuit of harness between ECM and inhibitor relay connector.
19
Go to step 20.
Check the following item and repair if necessary. Blown out of fuse Open or ground short circuit of harness between ignition switch connector and inhibitor relay connector Replace the inhibitor relay.
20
Repair the open circuit of harness between TCM and inhibitor relay connector.
Repair the open circuit of harness between inhibitor relay connector and starter relay connector.
EN(H4DOTC)(diag)-70

MAIN RELAY 3 5 6 4 2 1 B47 No.12 1 C23 B2 A7 B5 B19 3 IGNITION SWITCH SBF-6 MAIN SBF TO OXYGEN SENSOR SBF-5 SBF-7 No.13
B72
BATTERY
A: B134 B: B135 ECM C: B136 D: B137 D1 D2 A5 D3 D7
34 35 36 37 40
B21 E2
B72
B47 1 3 5 2 4 6
B21
A: 1 8 9 18 19 28 29 2 10 20 30
B134
B:
B135
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-05666
EN(H4DOTC)(diag)-71

Step Check Yes CHECK MAIN RELAY. Is the resistance less than 1 :? Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the main relay. 3) Connect the battery to main relay terminals No. 1 and No. 2. 4) Measure the resistance between main relay terminals. Terminals No. 3 No. 5: No. 4 No. 6: CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? Go to step 3. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 5 (+) Chassis ground (): (B135) No. 19 (+) Chassis ground (): CHECK INPUT VOLTAGE OF MAIN RELAY. Measure the voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 2 (+) Chassis ground (): (B47) No. 5 (+) Chassis ground (): (B47) No. 6 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Install the main relay. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 23 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Connect the connector to ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): Is the voltage 10 V or more? Go to step 4. No Replace the main relay. <Ref. to EN(H4DOTC)(diag) -8, Electrical Component Location.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and engine ground terminal Poor contact of coupling connector Repair the open or ground short circuit of harness of power supply circuit.
Go to step 5.
Go to step 6.
Repair the open or ground short circuit of harness between ECM and main relay connector.
Check ignition control system. <Ref. to EN(H4DOTC)(diag) -73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and main relay connector Poor contact of main relay connector
EN(H4DOTC)(diag)-72


B137 ECM
18
19
20
21
BATTERY MAIN SBF SBF-6 3
IGNITION SWITCH No. 12 1 B72
E
B21 49 20 31 E2 10 41 E34 3 1 2 9
E31 3 1 2 3 1 2
E32 3 1 2
E33
IGNITION COIL No. 1 E31 E32 E33 E34 1 2 3 B21 B72
IGNITION COIL No. 2 B137
IGNITION COIL No. 3
IGNITION COIL No. 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN(H4DOTC)(diag)-73
26
EN-06952

Step CHECK SPARK PLUG CONDITION. 1) Remove the spark plug. <Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.> 2) Check the spark plug condition. <Ref. to IG(H4DOTC)-5, INSPECTION, Spark Plug.> CHECK IGNITION SYSTEM FOR SPARKS. 1) Connect the spark plug to ignition coil. 2) Release the fuel pressure. <Ref. to FU(H4DOTC)-57, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Contact the spark plugs thread portion to the engine. 4) While opening the throttle valve fully, crank the engine to check that spark occurs at each cylinder. CHECK POWER SUPPLY CIRCUIT OF IGNITION COIL. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition coil. 3) Turn the ignition switch to ON. 4) Measure the voltage between ignition coil connector and engine ground. Connector & terminal (E31) No. 3 (+) Engine ground (): (E32) No. 3 (+) Engine ground (): (E33) No. 3 (+) Engine ground (): (E34) No. 3 (+) Engine ground (): CHECK HARNESS OF IGNITION COIL GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between ignition coil connector and engine ground. Connector & terminal (E31) No. 2 Engine ground: (E32) No. 2 Engine ground: (E33) No. 2 Engine ground: (E34) No. 2 Engine ground: Check Yes Is the spark plug condition nor- Go to step 2. mal? No Replace the spark plug. <Ref. to IG(H4DOTC)-4, Spark Plug.>
Does spark occur at each cylin- Check fuel pump Go to step 3. der? system. <Ref. to EN(H4DOTC)(diag) -76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
Go to step 4.
Repair the harness and connector. NOTE: In this case, repair the following item: Open harness between ignition coil and ignition switch connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and ignition coil connector Open circuit in harness between ECM and engine ground terminal Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and ignition coil connector Poor contact of coupling connector
CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 :? Go to step 6. NITION COIL CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and ignition coil connector. Connector & terminal (B137) No. 18 (E31) No. 1: (B137) No. 19 (E32) No. 1: (B137) No. 20 (E33) No. 1: (B137) No. 21 (E34) No. 1:
EN(H4DOTC)(diag)-74

Step CHECK HARNESS BETWEEN ECM AND IGNITION COIL CONNECTOR. Measure the resistance of harness between ECM and engine ground. Connector & terminal (B137) No. 18 Engine ground: (B137) No. 19 Engine ground: (B137) No. 20 Engine ground: (B137) No. 21 Engine ground: CHECK POOR CONTACT. Check for poor contact of the ECM connector. Check Is the resistance 1 M: or more? Yes Go to step 7. No Repair the ground short circuit of harness between ECM and ignition coil connector.
Replace the ignition coil. <Ref. to IG(H4DOTC)-7, Ignition Coil.>
EN(H4DOTC)(diag)-75


BATTERY No.11 2 FUEL PUMP RELAY 7 20 B97 R1 1 B362
10
E
FUEL PUMP CONTROL UNIT R122
R46 R67 19 8 3 5
9 8 B33 C12 ECM
FUEL PUMP R58
5 R1 B97
B: B135 C: B136
B362
R58
R122
B:
B135
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2
3 4
5 7 8 6
1 2 3 4 5 6
R67 1 2 3 4 5 6
3 4 1 2 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05083
Step Check CHECK OPERATING SOUND OF FUEL Does the fuel pump emit operPUMP. ating sound? Make sure that the fuel pump operates for two seconds when turning the ignition switch to ON. NOTE: Fuel pump operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.>
Yes Check the fuel injector circuit. <Ref. to EN(H4DOTC)(diag) -77, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
No Display the DTC. <Ref. to EN(H4DOTC)(diag) -42, OPERATION, Read Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-76


CAUTION: Check or repair only faulty parts. After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 SBF-7 6 4 2 1 B47 B137 ECM 11 BATTERY
10
54
48
53
52
51 E6 2 #4 1
B21 E2
E5 2 1 1 2
E16 2 1
E17
#1
#2
#3
FUEL INJECTOR
E5 E16
E6 E17
B21
B47 1 3 5 2 4 6
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05668
EN(H4DOTC)(diag)-77

Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel injector emit TOR. operating sound? While cranking the engine, check each fuel injector emits operating sound. Use a sound scope or attach a screwdriver to the injector for this check. CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more? JECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel injector connector and the engine ground. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground (): Yes No Check the fuel Go to step 2. pressure. <Ref. to ME(H4DOTC)-25, INSPECTION, Fuel Pressure.> Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and fuel injector connector Poor contact of main relay connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and fuel injector connector.
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. FUEL INJECTOR CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and fuel injector connector. Connector & terminal (B137) No. 8 (E5) No. 1: (B137) No. 9 (E16) No. 1: (B137) No. 10 (E6) No. 1: (B137) No. 11 (E17) No. 1: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 8 Chassis ground: (B137) No. 9 Chassis ground: (B137) No. 10 Chassis ground: (B137) No. 11 Chassis ground: CHECK EACH FUEL INJECTOR. Measure the resistance between each fuel injector terminals. Terminals No. 1 No. 2: CHECK POOR CONTACT. Check for poor contact of the ECM connector. Is the resistance 1 M: or more? Go to step 5.
Replace the faulty fuel injector. <Ref. to FU(H4DOTC)38, Fuel Injector.> Inspection using General Diagnostic Table <Ref. to EN(H4DOTC)(diag) -370, INSPECTION, General Diagnostic Table.>
EN(H4DOTC)(diag)-78


BATTERY No. 13
ECM A: B134 C: B136 D: B137
C16 C6
34 35 36 37 40 E2
* *
B122
D1 D2 A5 D3 D7 B21
B40 1 2 3 4 5 6 7 8
B122 1 8 9 18 19 28 29
A: 2 10 20 30
B134
B21 9 10 11 12 13 14 15 16
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2 3 4 5 6 7 8
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06954
EN(H4DOTC)(diag)-79

Step Check CHECK POWER SUPPLY CIRCUIT. Does SDI or general scan tool Connect the SDI (Subaru Diagnosis Interface) turn ON? or general scan tool to data link connector. CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 V or more? Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 16 (+) Chassis ground (): Yes Go to step 4. No Go to step 2.
Repair the power supply circuit. NOTE: In this case, repair the following item: Open or ground short circuit of harness between battery and data link connector Blown out of fuse (M/B No. 13) CHECK HARNESS BETWEEN DATA LINK Is the resistance less than 5 :? Repair the poor Repair the harness CONNECTOR AND CHASSIS GROUND. contact of data link and connector. 1) Turn the ignition switch to OFF. connector. NOTE: 2) Measure the resistance of harness between In this case, repair data link connector and chassis ground. the following item: Connector & terminal Open circuit of (B40) No. 4 Chassis ground: harness between (B40) No. 5 Chassis ground: ECM and data link connector Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 5. Repair the open DATA LINK CONNECTOR. circuit of harness 1) Disconnect the connector from ECM, TCM, between ECM and VDC CU, airbag CM and body integrated unit. data link connector. CAUTION: When disconnecting the connector from airbag control module, always follow the precautions on AB section. <Ref. to AB-4, CAUTION, General Description.> 2) Measure the resistance of harness between ECM and data link connector. Connector & terminal (B136) No. 16 (B40) No. 7: CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Repair the poor Repair the ground DATA LINK CONNECTOR. more? contact in the ECM short circuit of harMeasure the resistance between data link conor data link conness between nector and chassis ground. nector. ECM and data link Connector & terminal connector. (B40) No. 7 Chassis ground:
Go to step 3.
EN(H4DOTC)(diag)-80


A: LIST
DTC P0011 Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank1) Crankshaft Position - Camshaft Position Correlation (Bank2) Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) MAP/MAF - Throttle Position Correlation Mass or Volume Air Flow Circuit Range/Performance Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Range/Performance Intake Air Temperature Sensor 1 Circuit Low Reference <Ref. to EN(H4DOTC)(diag)-89, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-90, DTC P0016 CRANKSHAFT POSITION CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-91, DTC P0018 CRANKSHAFT POSITION CAMSHAFT POSITION CORRELATION (BANK2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-92, DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-93, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-95, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-97, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-99, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-101, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-103, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-105, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-107, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-109, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-111, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-113, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-115, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-117, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0016
P0018
P0021
P0030
P0031
P0032
P0037
P0038
P0068
P0101
P0102
P0103
P0107
P0108
P0111
P0112
EN(H4DOTC)(diag)-81

DTC P0113 Item Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/ Switch A Circuit Low Throttle/Pedal Position Sensor/ Switch A Circuit High Insufficient Coolant Temperature for Closed Loop Fuel Control Insufficient Engine Coolant Temperature For Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) System Too Lean (Bank 1) System Too Rich (Bank 1) Fuel Temperature Sensor A Circuit Range/Performance Reference <Ref. to EN(H4DOTC)(diag)-119, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-121, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-123, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-125, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-127, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-129, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-130, DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-132, DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-133, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-135, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-137, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-139, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-141, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-143, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-145, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-147, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-149, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-150, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-152, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0117
P0118
P0122
P0123
P0125
P0126
P0128
P0131
P0132
P0133
P0134
P0137
P0138
P0139
P0140
P0171 P0172 P0181
EN(H4DOTC)(diag)-82

DTC P0182 Item Fuel Temperature Sensor A Circuit Low Input Fuel Temperature Sensor A Circuit High Input Throttle/Pedal Position Sensor/ Switch B Circuit Low Reference <Ref. to EN(H4DOTC)(diag)-154, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-156, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0183
P0222
P0223
P0230 P0244
P0245
P0246
P0301 P0302 P0303 P0304 P0327
P0328
P0335
P0336
P0340
P0345
<Ref. to EN(H4DOTC)(diag)-158, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H4DOTC)(diag)-160, DTC P0223 THROTTLE/PEDAL POSISwitch B Circuit High TION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Pump Primary Circuit <Ref. to EN(H4DOTC)(diag)-162, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Turbo/Super Charger Wastegate <Ref. to EN(H4DOTC)(diag)-165, DTC P0244 TURBO/SUPER CHARGER Solenoid A Range/Performance WASTEGATE SOLENOID A RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Turbo/Super Charger Wastegate <Ref. to EN(H4DOTC)(diag)-167, DTC P0245 TURBO/SUPER CHARGER Solenoid A Low WASTEGATE SOLENOID A LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Turbo/Super Charger Wastegate <Ref. to EN(H4DOTC)(diag)-169, DTC P0246 TURBO/SUPER CHARGER Solenoid A High WASTEGATE SOLENOID A HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 1 Misfire Detected <Ref. to EN(H4DOTC)(diag)-170, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 2 Misfire Detected <Ref. to EN(H4DOTC)(diag)-170, DTC P0302 CYLINDER 2 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 3 Misfire Detected <Ref. to EN(H4DOTC)(diag)-170, DTC P0303 CYLINDER 3 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 4 Misfire Detected <Ref. to EN(H4DOTC)(diag)-171, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 1 Circuit Low (Bank <Ref. to EN(H4DOTC)(diag)-177, DTC P0327 KNOCK SENSOR 1 CIRCUIT 1 or Single Sensor) LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 1 Circuit High (Bank <Ref. to EN(H4DOTC)(diag)-179, DTC P0328 KNOCK SENSOR 1 CIRCUIT 1 or Single Sensor) HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft Position Sensor A Cir- <Ref. to EN(H4DOTC)(diag)-181, DTC P0335 CRANKSHAFT POSITION cuit SENSOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft Position Sensor A Cir- <Ref. to EN(H4DOTC)(diag)-183, DTC P0336 CRANKSHAFT POSITION cuit Range/Performance SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Camshaft Position Sensor A Cir- <Ref. to EN(H4DOTC)(diag)-185, DTC P0340 CAMSHAFT POSITION SENcuit (Bank 1 or Single Sensor) SOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Camshaft Position Sensor A Cir- <Ref. to EN(H4DOTC)(diag)-187, DTC P0345 CAMSHAFT POSITION SENcuit (Bank 2) SOR A CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System Secondary Air Injection System Incorrect Flow Detected <Ref. to EN(H4DOTC)(diag)-189, DTC P0410 SECONDARY AIR INJECTION SYSTEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-193, DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0410 P0411
EN(H4DOTC)(diag)-83

DTC P0413 Item Secondary Air Injection System Switching Valve A Circuit Open Reference <Ref. to EN(H4DOTC)(diag)-196, DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-199, DTC P0414 SECONDARY AIR INJECSwitching Valve A Circuit Shorted TION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-202, DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-205, DTC P0417 SECONDARY AIR INJECSwitching Valve B Circuit Shorted TION SYSTEM SWITCHING VALVE B CIRCUIT SHORTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-208, DTC P0418 SECONDARY AIR INJECControl A Circuit TION SYSTEM CONTROL A CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Catalyst System Efficiency below <Ref. to EN(H4DOTC)(diag)-211, DTC P0420 CATALYST SYSTEM EFFIThreshold (Bank 1) CIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Cont. Sys. <Ref. to EN(H4DOTC)(diag)-215, DTC P0441 EVAPORATIVE EMISSION Incorrect Purge Flow SYSTEM INCORRECT PURGE FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-216, DTC P0442 EVAPORATIVE EMISSION tem Leak Detected (Small Leak) CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-219, DTC P0447 EVAPORATIVE EMISSION tem Vent Control Circuit Open CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-221, DTC P0448 EVAPORATIVE EMISSION tem Vent Control Circuit Shorted CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-223, DTC P0451 EVAPORATIVE EMISSION tem Pressure Sensor CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-225, DTC P0452 EVAPORATIVE EMISSION tem Pressure Sensor Low Input CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-227, DTC P0453 EVAPORATIVE EMISSION tem Pressure Sensor High Input CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-229, DTC P0456 EVAPORATIVE EMISSION tem Leak Detected (Very Small CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Leak) Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-232, DTC P0457 EVAPORATIVE EMISSION tem Leak Detected (Fuel Cap CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), DiagLoose/Off) nostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission System <Ref. to EN(H4DOTC)(diag)-235, DTC P0458 EVAPORATIVE EMISSION Purge Control Valve Circuit Low SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission System <Ref. to EN(H4DOTC)(diag)-237, DTC P0459 EVAPORATIVE EMISSION Purge Control Valve Circuit High SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Level Sensor A Circuit <Ref. to EN(H4DOTC)(diag)-239, DTC P0461 FUEL LEVEL SENSOR A Range/Performance CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Level Sensor A Circuit Low <Ref. to EN(H4DOTC)(diag)-239, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System Switching Valve B Circuit Open
P0414
P0416
P0417
P0418
P0420
P0441
P0442
P0447
P0448
P0451
P0452
P0453
P0456
P0457
P0458
P0459
P0461
P0462
EN(H4DOTC)(diag)-84

DTC P0463 Item Fuel Level Sensor A Circuit High Reference <Ref. to EN(H4DOTC)(diag)-239, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-240, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-240, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-241, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-243, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-245, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-16, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-246, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-247, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-248, DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-249, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-250, DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-250, DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-2, Basic Diagnostic Procedure.> <Ref. to EN(H4DOTC)(diag)-251, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-2, Basic Diagnostic Procedure.> <Ref. to EN(H4DOTC)(diag)-253, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-255, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-257, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-258, DTC P1160 RETURN SPRING FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-259, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0464
Fuel Level Sensor Circuit Intermittent Vehicle Speed Sensor A Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Starter Request Circuit Incorrect Immobilizer Key Serial Communication Link Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/ Performance (Bank 1) Transmission Control System (MIL Request) Park/Neutral Switch Input Circuit Low (AT Model) Neutral Switch Input Circuit Low (MT Model) Park/Neutral Switch Input Circuit High (AT Model) Neutral Switch Input Circuit High (MT Model) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Fuel Tank Pressure Control Solenoid Valve Circuit Low
P0500 P0506
P0507
P0512 P0513 P0600 P0604
P0605
P0607
P0638
P0700
P0851 P0851
P0852 P0852
P1152
P1153
P1160 P1400
EN(H4DOTC)(diag)-85

DTC P1410 Item Secondary Air Injection System Switching Valve Stuck Open Secondary Air Injection System Control A Circuit Shorted Fuel Tank Pressure Control Sol. Valve Circuit High Reference <Ref. to EN(H4DOTC)(diag)-261, DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-264, DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1418
P1420
P1443
P1491
P1560
P1570 P1571 P1572
P1574 P1576 P1577 P1578 P1602
P2004
P2005
P2006
P2007
P2008
P2009
<Ref. to EN(H4DOTC)(diag)-267, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Vent Control Solenoid Valve Func- <Ref. to EN(H4DOTC)(diag)-269, DTC P1443 VENT CONTROL SOLENOID tion Problem VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Positive Crankcase Ventilation <Ref. to EN(H4DOTC)(diag)-271, DTC P1491 POSITIVE CRANKCASE (Blow-by) Function Problem VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Back-Up Voltage Circuit Malfunc<Ref. to EN(H4DOTC)(diag)-273, DTC P1560 BACK-UP VOLTAGE CIRtion CUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Antenna <Ref. to IM(diag)-17, DTC P1570 ANTENNA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Reference Code Incompatibility <Ref. to IM(diag)-19, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> IMM Circuit Failure (Except <Ref. to IM(diag)-20, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT Antenna Circuit) ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Key Communication Failure <Ref. to IM(diag)-23, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> EGI Control Module EEPROM <Ref. to IM(diag)-23, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> IMM Control Module EEPROM <Ref. to IM(diag)-24, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Meter Failure <Ref. to IM(diag)-24, DTC P1578 METER FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Control Module Programming Error <Ref. to EN(H4DOTC)(diag)-275, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Control <Ref. to EN(H4DOTC)(diag)-284, DTC P2004 INTAKE MANIFOLD RUNStuck Open (Bank 1) NER CONTROL STUCK OPEN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Control <Ref. to EN(H4DOTC)(diag)-284, DTC P2005 INTAKE MANIFOLD RUNStuck Open (Bank 2) NER CONTROL STUCK OPEN (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Control <Ref. to EN(H4DOTC)(diag)-285, DTC P2006 INTAKE MANIFOLD RUNStuck Closed (Bank 1) NER CONTROL STUCK CLOSED (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Control <Ref. to EN(H4DOTC)(diag)-286, DTC P2007 INTAKE MANIFOLD RUNStuck Closed (Bank 2) NER CONTROL STUCK CLOSED (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Control <Ref. to EN(H4DOTC)(diag)-287, DTC P2008 INTAKE MANIFOLD RUNCircuit / Open (Bank 1) NER CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Control <Ref. to EN(H4DOTC)(diag)-289, DTC P2009 INTAKE MANIFOLD RUNCircuit Low (Bank 1) NER CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-86

DTC P2011 Item Intake Manifold Runner Control Circuit / Open (Bank 2) Intake Manifold Runner Control Circuit Low (Bank 2) Reference <Ref. to EN(H4DOTC)(diag)-291, DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-293, DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2012
P2016
P2017
P2021
P2022
P2088
P2089
P2092
P2093
P2096
P2097
P2101
P2102
P2103
P2109
P2122
P2123
P2127
Intake Manifold Runner Position <Ref. to EN(H4DOTC)(diag)-295, DTC P2016 INTAKE MANIFOLD RUNSensor / Switch Circuit Low (Bank 1) NER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Position <Ref. to EN(H4DOTC)(diag)-297, DTC P2017 INTAKE MANIFOLD RUNSensor / Switch Circuit High (Bank 1) NER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Position <Ref. to EN(H4DOTC)(diag)-299, DTC P2021 INTAKE MANIFOLD RUNSensor / Switch Circuit Low (Bank 2) NER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Manifold Runner Position <Ref. to EN(H4DOTC)(diag)-301, DTC P2022 INTAKE MANIFOLD RUNSensor / Switch Circuit High (Bank 2) NER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Camshaft Position Actuator <Ref. to EN(H4DOTC)(diag)-303, DTC P2088 INTAKE CAMSHAFT POSIControl Circuit Low (Bank 1) TION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Camshaft Position Actuator <Ref. to EN(H4DOTC)(diag)-305, DTC P2089 INTAKE CAMSHAFT POSIControl Circuit High (Bank 1) TION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Camshaft Position Actuator <Ref. to EN(H4DOTC)(diag)-307, DTC P2092 INTAKE CAMSHAFT POSIControl Circuit Low (Bank 2) TION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Camshaft Position Actuator <Ref. to EN(H4DOTC)(diag)-309, DTC P2093 INTAKE CAMSHAFT POSIControl Circuit High (Bank 2) TION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Post Catalyst Fuel Trim System <Ref. to EN(H4DOTC)(diag)-310, DTC P2096 POST CATALYST FUEL TRIM Too Lean (Bank1) SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Post Catalyst Fuel Trim System <Ref. to EN(H4DOTC)(diag)-311, DTC P2097 POST CATALYST FUEL TRIM Too Rich (Bank1) SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle Actuator Control Motor Cir- <Ref. to EN(H4DOTC)(diag)-318, DTC P2101 THROTTLE ACTUATOR cuit Range/Performance CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle Actuator Control Motor Cir- <Ref. to EN(H4DOTC)(diag)-323, DTC P2102 THROTTLE ACTUATOR cuit Low CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle Actuator Control Motor Cir- <Ref. to EN(H4DOTC)(diag)-325, DTC P2103 THROTTLE ACTUATOR cuit High CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor A <Ref. to EN(H4DOTC)(diag)-326, DTC P2109 THROTTLE/PEDAL POSIMinimum Stop Performance TION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H4DOTC)(diag)-327, DTC P2122 THROTTLE/PEDAL POSISwitch D Circuit Low Input TION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H4DOTC)(diag)-329, DTC P2123 THROTTLE/PEDAL POSISwitch D Circuit High Input TION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H4DOTC)(diag)-331, DTC P2127 THROTTLE/PEDAL POSISwitch E Circuit Low Input TION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-87

DTC P2128 Item Throttle/Pedal Position Sensor/ Switch E Circuit High Input Throttle/Pedal Position Sensor/ Switch A/B Voltage Correlation Throttle/Pedal Position Sensor/ Switch D/E Voltage Correlation Reference <Ref. to EN(H4DOTC)(diag)-333, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-335, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2135
P2138
P2419
P2420
P2431
P2432
P2433
P2440
P2441
P2442
P2443
P2444
<Ref. to EN(H4DOTC)(diag)-338, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission System <Ref. to EN(H4DOTC)(diag)-340, DTC P2419 EVAPORATIVE EMISSION Switching Valve Control Circuit SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic ProceLow dure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-342, DTC P2420 EVAPORATIVE EMISSION Evaporative Emission System Switching Valve Control Circuit SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic ProHigh cedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System Air <Ref. to EN(H4DOTC)(diag)-344, DTC P2431 SECONDARY AIR INJECFlow /Pressure Sensor Circuit TION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERRange/Performance FORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System Air <Ref. to EN(H4DOTC)(diag)-347, DTC P2432 SECONDARY AIR INJECFlow /Pressure Sensor Circuit Low TION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System Air <Ref. to EN(H4DOTC)(diag)-350, DTC P2433 SECONDARY AIR INJECFlow /Pressure Sensor Circuit High TION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-353, DTC P2440 SECONDARY AIR INJECSwitching Valve Stuck Open TION SYSTEM SWITCHING VALVE STUCK OPEN (BANK1), Diagnostic (Bank1) Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-357, DTC P2441 SECONDARY AIR INJECSwitching Valve Stuck Closed TION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK1), Diagnostic (Bank1) Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-358, DTC P2442 SECONDARY AIR INJECSwitching Valve Stuck Open TION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic (Bank2) Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-362, DTC P2443 SECONDARY AIR INJECSwitching Valve Stuck Closed TION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK2), Diagnostic (Bank2) Procedure with Diagnostic Trouble Code (DTC).> Secondary Air Injection System <Ref. to EN(H4DOTC)(diag)-363, DTC P2444 SECONDARY AIR INJECPump Stuck On TION SYSTEM PUMP STUCK ON, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-88


A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-10, DTC P0011 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle using the Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0? Yes Go to step 2. No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H4SO)-10, REPLACEMENT, Engine Oil.> <Ref. to LU(H4SO)-23, Engine Oil Filter.>
When the oil flow control solenoid valve duty output exceeds 10%, is the AVCS system operating angle approx. 0?
Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft)
EN(H4DOTC)(diag)-89

B: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0, and oil flow control solenoid valve duty output approx. 10%? Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H4SO)-10, REPLACEMENT, Engine Oil.> <Ref. to LU(H4SO)-23, Engine Oil Filter.> No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Timing belt (matching of timing mark)
EN(H4DOTC)(diag)-90

C: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-13, DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0, and oil flow control solenoid valve duty output approx. 10%? Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H4SO)-10, REPLACEMENT, Engine Oil.> <Ref. to LU(H4SO)-23, Engine Oil Filter.> No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Timing belt (matching of timing mark)
EN(H4DOTC)(diag)-91

D: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-13, DTC P0021 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle using the Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0? Yes Go to step 2. No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H4SO)-10, REPLACEMENT, Engine Oil.> <Ref. to LU(H4SO)-23, Engine Oil Filter.>
EN(H4DOTC)(diag)-92

E: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-14, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY SBF-5 5 3 6 4 2 1 B47 FRONT OXYGEN (A/F) SENSOR E79 2 3 1 4 B21 E2 BATTERY E79
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669
EN(H4DOTC)(diag)-93

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 3 (E79) No. 2: (B136) No. 2 (E79) No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 9 (E79) No. 1: (B135) No. 8 (E79) No. 3: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 4. Replace the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.> Repair the poor Replace the front contact in ECM or oxygen (A/F) senfront oxygen (A/F) sor. <Ref. to sensor connector. FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.>
Is the resistance less than 2 3 :?
EN(H4DOTC)(diag)-94


DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-16, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669
EN(H4DOTC)(diag)-95

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E79) No. 4 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. NOTE: In this case, repair the following item: Open circuit of harness between main relay and front oxygen (A/F) sensor connector Poor contact of main relay connector Poor contact of coupling connector Malfunction of main relay Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Replace the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.>
EN(H4DOTC)(diag)-96


DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-18, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669
EN(H4DOTC)(diag)-97

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 3 (+) Chassis ground (): (B136) No. 2 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and front oxygen (A/F) sensor connector.
EN(H4DOTC)(diag)-98

H: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-20, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY SBF-5 5 3 6 4 2 1 B47 REAR OXYGEN SENSOR T6 B19 2 T5 2 BATTERY B19 T6 1 2 3 4 B83 B138 B47
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 * *
B30 C4 B4 B1 2 2
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
: TERMINAL No. OPTIONAL ARRANGEMENT : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670
EN(H4DOTC)(diag)-99

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (T6) No. 2 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. NOTE: In this case, repair the following item: Open circuit of harness between main relay and rear oxygen sensor Poor contact of main relay connector Poor contact of coupling connector Malfunction of main relay Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and rear oxygen sensor Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Replace the rear oxygen sensor. <Ref. to FU(H4DOTC)-48, Rear Oxygen Sensor.>
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between the ECM and oxygen sensor connector. Connector & terminal (B136) No. 4 (T6) No. 1:
CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor connector terminals. Terminals No. 1 No. 2:
EN(H4DOTC)(diag)-100

I:
DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-22, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 * *
B30 C4 B4 B1 2 2
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 4 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and rear oxygen sensor connector. Repair the poor contact of ECM connector. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector

J: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-24, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E21
1 2 3
2 1 3
E21
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 E2 23 6 28 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
6 29 19 ECM
EN-05671

Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK MANIFOLD ABSOLUTE PRESSURE Is the measured value 73.3 Go to step 3. SENSOR. 106.6 kPa (550 800 mmHg, 1) Start the engine and warm up engine until 21.65 31.50 inHg) when the coolant temperature is higher than 75C ignition is turned ON, and 20.0 (167F). 46.7 kPa (150 350 mmHg, 2) For AT models, set the select lever to P 5.91 13.78 inHg) during range or N range, and for MT models, place idling? the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the General Scan Tool Instruction Manual. CHECK THROTTLE OPENING ANGLE. Is the measured value less than Go to step 4. Read the data of throttle position signal using 5% when throttle is fully Subaru Select Monitor or general scan tool. closed? NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the General Scan Tool Instruction Manual. CHECK THROTTLE OPENING ANGLE. Is the measured value 85% or Replace the manimore when throttle is fully fold absolute presopen? sure sensor. <Ref. to FU(H4DOTC)37, Manifold Absolute Pressure Sensor.> Step CHECK AIR INTAKE SYSTEM. No Go to step 2.
Replace the manifold absolute pressure sensor. <Ref. to FU(H4DOTC)37, Manifold Absolute Pressure Sensor.>
Replace the electronic throttle control. <Ref. to FU(H4DOTC)-14, Throttle Body.>

K: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-26, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4
ECM
* *
B83
35
26
30
B135
B3
18
34
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-05087

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> No Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4DOTC)-36, Mass Air Flow and Intake Air Temperature Sensor.>

L: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-28, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4
ECM
* *
B83
35
26
30
B135
B3
18
34
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-05087

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF MASS AIR Is the voltage 10 V or more? FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the mass air flow and intake air temperature sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 1 (+) Engine ground (): Go to step 3. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and mass air flow and intake air temperature sensor connector Poor contact of main relay connector Repair the open circuit of harness between ECM and mass air flow and intake air temperature sensor connector.
Go to step 5.
Repair the ground short circuit of harness between the ECM and the mass air flow and intake air temperature sensor connectors. Repair any poor Replace the mass contact in the ECM air flow and intake or the mass air flow air temperature and intake air tem- sensor. <Ref. to perature sensor FU(H4DOTC)-36, Mass Air Flow and connector. Intake Air Temperature Sensor.>

M: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-29, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4
ECM
* *
B83
35
26
30
B135
B3
18
34
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-05087

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the mass air flow and intake air temperature sensor. 3) Start the engine. 4) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 2 Engine ground: Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: pen circuit of harness between ECM and the mass air flow and intake air temperature sensor connector. Poor contact in ECM connector CHECK POOR CONTACT. Is there poor contact in the Repair any poor Replace the mass Check for any poor contact in the mass air flow mass air flow and intake air contact of the air flow and intake and intake air temperature sensor connector. temperature sensor connector? mass air flow and air temperature intake air temperasensor. <Ref. to ture sensor conFU(H4DOTC)-36, nector. Mass Air Flow and Intake Air Temperature Sensor.>
Go to step 4.

N: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-30, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E21
1 2 3
2 1 3
E21
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 E2 23 6 28 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
6 29 19 ECM
EN-05671

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Start the engine. 13.3 kPa (100 mmHg, 3.94 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF MANIFOLD Is the voltage 4.5 V or more? Go to step 3. ABSOLUTE PRESSURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) Engine ground (): No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact in ECM connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact of coupling connector Repair ground short circuit of harness between ECM and manifold absolute pressure sensor connector. Replace the manifold absolute pressure sensor. <Ref. to FU(H4DOTC)37, Manifold Absolute Pressure Sensor.>
Go to step 5.

O: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-31, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E21
1 2 3
2 1 3
E21
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 E2 23 6 28 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
6 29 19 ECM
EN-05671

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Start the engine. 4) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 1 Engine ground: Check Yes Is the measured value 119.5 kPa Go to step 2. (896.5 mmHg, 35.29 inHg) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact in ECM connector Poor contact of coupling connector Replace the maniRepair the poor fold absolute prescontact of manifold absolute pressure sensor. <Ref. to FU(H4DOTC)sure sensor connector. 37, Manifold Absolute Pressure Sensor.>

P: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-32, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4
ECM
* *
B83
35
26
30
B135
B3
18
34
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-05087

Step Check CHECK ENGINE COOLANT TEMPERAIs the engine coolant temperaTURE. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Measure the engine coolant temperature using the Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Yes Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4DOTC)-36, Mass Air Flow and Intake Air Temperature Sensor.> No Check DTC P0125 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).>

Q: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-34, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4
ECM
* *
B83
35
26
30
B135
B3
18
34
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-05087

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and mass air flow and intake air temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 18 Chassis ground: Check Is the intake air temperature 120C (248F) or higher? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the ground short circuit of harness between the ECM and the mass air flow and intake air temperature sensor connectors.
Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4DOTC)-36, Mass Air Flow and Intake Air Temperature Sensor.>

R: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-35, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4
ECM
* *
B83
35
26
30
B135
B3
18
34
B47
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 3 5
2 4 6
1 2 3 4 5 6 7 8
EN-05087

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact in the ECM or the mass air flow and intake air temperature sensor connector. Check Is the intake air temperature less than 40C (40F) ? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair any poor contact in the ECM or the mass air flow and intake air temperature sensor connector. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the open MASS AIR FLOW AND INTAKE AIR TEMcircuit of harness PERATURE SENSOR CONNECTOR. between ECM and 1) Turn the ignition switch to OFF. mass air flow and 2) Disconnect the connector from ECM and intake air temperamass air flow and intake air temperature sensor. ture sensor con3) Measure the resistance of harness between nector. ECM and mass air flow and intake air temperature sensor connectors. Connector & terminal (B135) No. 18 (B3) No. 4: (B135) No. 30 (B3) No. 5: CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? Repair the short Replace the mass MASS AIR FLOW AND INTAKE AIR TEMcircuit to power in air flow and intake PERATURE SENSOR CONNECTOR. the harness air temperature 1) Connect all connectors. between the ECM sensor. <Ref. to 2) Turn the ignition switch to OFF. and the mass air FU(H4DOTC)-36, 3) Measure the voltage between ECM and flow and intake air Mass Air Flow and chassis ground. temperature sen- Intake Air TemperConnector & terminal sor connector. ature Sensor.> (B135) No. 18 (+) Chassis ground ():

S: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-36, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
ENGINE COOLANT TEMPERATURE SENSOR E8 2 1
E8
1 2
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 E2 12 6 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 ECM
34 29
EN-05672

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 34 Chassis ground: Check Yes Is the engine coolant tempera- Go to step 2. ture 150C (302F) or higher? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the short circuit to ground in harness between ECM and engine coolant temperature sensor.
Replace the engine coolant temperature sensor. <Ref. to FU(H4DOTC)-31, Engine Coolant Temperature Sensor.>

T: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-37, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E8
1 2
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 E2 12 6 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 ECM
34 29
EN-05672

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact in ECM and engine coolant temperature sensor connector. Check Yes Is the engine coolant tempera- Go to step 2. ture less than 40C (40F) ? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is there poor contact in ECM or Repair the poor engine coolant temperature contact in ECM or engine coolant sensor connector? temperature sensor connector. CHECK HARNESS BETWEEN ECM AND EN- Is the resistance less than 1 :? Go to step 4. Repair the harness GINE COOLANT TEMPERATURE SENSOR and connector. CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM and the following item: engine coolant temperature sensor. Open circuit in 3) Measure the resistance of harness between harness between ECM and engine coolant temperature sensor ECM and engine connector. coolant temperaConnector & terminal ture sensor con(B134) No. 34 (E8) No. 2: nector (B134) No. 29 (E8) No. 1: Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND EN- Is the voltage 5 V or more? Repair the short Replace the GINE COOLANT TEMPERATURE SENSOR circuit to power in engine coolant CONNECTOR. harness between temperature sen1) Connect all connectors. ECM and engine sor. <Ref. to 2) Turn the ignition switch to ON. coolant tempera- FU(H4DOTC)-31, 3) Measure the voltage between ECM and ture sensor conEngine Coolant chassis ground. nector. Temperature SenConnector & terminal sor.> (B134) No. 34 (+) Chassis ground ():

U: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-38, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
ELECTRONIC THROTTLE CONTROL RELAY 7 5 6 8 C21 BATTERY B362 SBF-7
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
4 : TERMINAL No. OPTIONAL ARRANGEMENT
E
ELECTRONIC THROTTLE CONTROL E57
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31
EN-05673

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).>

V: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-39, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31
EN-05673

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 (E57) No. 6: (B134) No. 29 (E57) No. 3: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? Go to step 3. ELECTRONIC THROTTLE CONTROL. 1) Connect the ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 Engine ground: No Repair the open circuit of harness between ECM and electronic throttle control connector.
Repair the short circuit to power in the harness between ECM and electronic throttle control connector. Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4DOTC)-14, Throttle Body.>

W: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-40, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine does not return to idle. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
Fill or replace the engine coolant. <Ref. to CO(H4DOTC)-14, REPLACEMENT, Engine Coolant.> Replace the ther- Replace the mostat. <Ref. to engine coolant CO(H4DOTC)-18, temperature senThermostat.> sor. <Ref. to FU(H4DOTC)-31, Engine Coolant Temperature Sensor.>

X: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-42, DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E8
1 2
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 E2 12 6 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134 ECM
34 29
EN-05672

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure the resistance between engine coolant temperature sensor terminals when the engine coolant is cold and after warmed up. Terminals No. 1 No. 2: Check Yes Is the resistance of engine cool- Repair the poor ant temperature sensor differ- contact of ECM ent between when engine connector. coolant is cold and after warmed up? No Replace the engine coolant temperature sensor. <Ref. to FU(H4DOTC)-31, Engine Coolant Temperature Sensor.>

Y: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-44, DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Thermostat remains open. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step CHECK ENGINE COOLANT. Check Are the coolant level and mixture ratio of engine coolant to anti-freeze solution correct? Yes Go to step 2. No Replace the engine coolant. <Ref. to CO(H4DOTC)-14, REPLACEMENT, Engine Coolant.> Repair radiator fan Replace the thercircuit. <Ref. to mostat. <Ref. to CO(H4DOTC)-25, CO(H4DOTC)-18, Radiator Main Fan Thermostat.> and Fan Motor.> and <Ref. to CO(H4DOTC)-27, Radiator Sub Fan and Fan Motor.>

Z: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-46, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 9 Chassis ground: (B135) No. 8 Chassis ground: CHECK POOR CONTACT. Check for poor contact in the front oxygen (A/F) sensor connector. Check Yes Has water entered the connec- Completely tor? remove any water inside. Is the resistance 1 M: or Go to step 3. more? No Go to step 2.
Replace the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.>

AA:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-48, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669

Replace the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.>

AB:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-50, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a hole Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.>

AC:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-53, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669

No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor. <Ref. to sensor connector. FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.> Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 9 (E79) No. 1: (B135) No. 8 (E79) No. 3:

AD:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-55, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 * *
B30 C4 B4 B1 2 2
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (T6) No. 3: (B135) No. 30 (T6) No. 4: No Go to step 2.
Go to step 3.
CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 0.5 V? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (T6) No. 3 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H4DOTC)-48, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Repair or replace Replace the rear faulty parts. oxygen sensor. <Ref. to FU(H4DOTC)-48, Rear Oxygen Sensor.>

AE:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-57, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 * *
B30 C4 B4 B1 2 2
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (T6) No. 3: (B135) No. 30 (T6) No. 4: No Go to step 2.
Go to step 3.
CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 0.5 V? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (T6) No. 3 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H4DOTC)-48, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Repair or replace Replace the rear faulty parts. oxygen sensor. <Ref. to FU(H4DOTC)-48, Rear Oxygen Sensor.>

AF:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-58, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 * *
B30 C4 B4 B1 2 2
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (T6) No. 3: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Is the resistance 1 M: or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 :? Replace the rear Even if DTC is oxygen sensor. detected, the cir<Ref. to cuit has returned to FU(H4DOTC)-48, a normal condition Rear Oxygen Sen- at this time. Reprosor.> duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (T6) No. 3 Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 No. 4

AG:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-63, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 *2 *2
B30 C4 B4 B1
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (T6) No. 3: (B135) No. 30 (T6) No. 4: Check Yes Is the voltage 490 mV or more? Go to step 6. No Go to step 2.
Go to step 3.
Go to step 4.

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 0.5 V? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (T6) No. 3 (+) Chassis ground (): Yes Replace the rear oxygen sensor. <Ref. to FU(H4DOTC)-48, Rear Oxygen Sensor.> No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Replace the rear oxygen sensor. <Ref. to FU(H4DOTC)-48, Rear Oxygen Sensor.>
AH:DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4DOTC)(diag)-150, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AI: DTC P0172 SYSTEM TOO RICH (BANK 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-66, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 2 Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 284 314 kPa (2.9 3.2 kg/cm2, WARNING: Place NO OPEN FLAMES signs near the 41 46 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. <Ref. to ME(H4DOTC)-25, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze the fuel return hose 2 to 3 times, then measure fuel pressure again. CHECK FUEL PRESSURE. Is the measured value 230 After connecting the pressure regulator vacuum 260 kPa (2.35 2.65 kg/cm2, 33 38 psi)? hose, measure fuel pressure. <Ref. to ME(H4DOTC)-25, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. If the measured value at this step is out of specification, check or replace pressure regulator and pressure regulator vacuum hose. Step CHECK EXHAUST SYSTEM. Yes No Repair the exhaust Go to step 2. system. Repair the air Go to step 3. intake system. Go to step 4. Repair the following item. Fuel pressure is too high: Clogged fuel return line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel supply line
Go to step 5.
Repair the following item. Fuel pressure is too high: Faulty pressure regulator Clogged fuel return line or bent hose Fuel pressure is too low: Faulty pressure regulator Improper fuel pump discharge Clogged fuel supply line

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Check Yes Is the engine coolant tempera- Go to step 6. ture 75C (167F) or higher? No Replace the engine coolant temperature sensor. <Ref. to FU(H4DOTC)-31, Engine Coolant Temperature Sensor.>
Is the measured value 2.0 5.0 g/s (0.26 0.66 lb/m)?
Go to step 7.
Check the mass air flow and intake air temperature sensor. <Ref. to FU(H4DOTC)-36, Mass Air Flow and Intake Air Temperature Sensor.>

AJ:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-67, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
FUEL TANK FUEL TEMPERATURE SENSOR
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
17 30
B135
ECM
:TERMINAL No. OPTIONAL ARRANGEMENT
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5 6 7 8
EN-03923

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> No Replace the fuel temperature sensor. <Ref. to EC(H4DOTC)-13, Fuel Temperature Sensor.>

AK:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-70, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
17 30
B135
ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5 6 7 8
EN-03923

Step Check CHECK CURRENT DATA. Is the temperature 120C 1) Start the engine. (248F) or higher? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Replace the fuel Repair the ground temperature sen- short circuit of harsor. <Ref. to ness between EC(H4DOTC)-13, ECM and fuel Fuel Temperature pump. Sensor.>

AL:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-71, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
17 30
B135
ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5 6 7 8
EN-03923

Step Check CHECK CURRENT DATA. Is the temperature less than 1) Start the engine. 40C (40F)? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance of the harness between the ECM and fuel temperature sensor connector. Connector & terminal (B135) No. 17 (R58) No. 2: (B135) No. 30 (R58) No. 3: CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 17 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and fuel temperature sensor connector Poor contact of coupling connector Repair the short Replace the fuel circuit to power in temperature senthe harness sor. <Ref. to between the ECM EC(H4DOTC)-13, and fuel tempera- Fuel Temperature ture sensor conSensor.> nector.

AM:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-72, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31
EN-05673

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).>

AN:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-73, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31
EN-05673

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? Go to step 3. ELECTRONIC THROTTLE CONTROL. 1) Connect the ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 Engine ground:
Repair the short circuit to power in the harness between ECM and electronic throttle control connector. Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4DOTC)-14, Throttle Body.>

AO:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-74, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY No.11 2 FUEL PUMP RELAY 7 20 B97 R1 1 B362
10
E
FUEL PUMP CONTROL UNIT R122
R46 R67 19 8 3 5
9 8 B33 C12 ECM
FUEL PUMP R58
5 R1 B97
B: B135 C: B136
B362
R58
R122
B:
B135
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2
3 4
5 7 8 6
1 2 3 4 5 6
R67 1 2 3 4 5 6
3 4 1 2 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05083

Step Check CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage 10 V or more? PUMP CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel pump control unit. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 10 (+) Chassis ground (): Yes Go to step 2. No Repair the power supply circuit. NOTE: In this case, repair the following item: Open or ground short circuit of harness between fuel pump relay and fuel pump control unit Poor contact of fuel pump control unit connector Poor contact of fuel pump relay connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit between fuel pump control unit and chassis ground Poor contact of fuel pump control unit connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between fuel pump control unit and fuel pump Poor contact of coupling connector Repair the ground short circuit of harness between fuel pump control unit and fuel pump.
CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5 :? Go to step 3. CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 5 Chassis ground:
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 :? Go to step 4. CONTROL UNIT AND FUEL PUMP CONNECTOR. 1) Disconnect the connector from fuel pump. 2) Measure the resistance of harness between fuel pump control unit and fuel pump connector. Connector & terminal (R122) No. 7 (R58) No. 5: (R122) No. 6 (R58) No. 6:
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance 1 M: or Go to step 5. CONTROL UNIT AND FUEL PUMP CONNEC- more? TOR. Measure the resistance between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 7 Chassis ground: (R122) No. 6 Chassis ground: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 6. FUEL PUMP CONTROL UNIT. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and fuel pump control unit. Connector & terminal (B135) No. 33 (R122) No. 9: (B136) No. 12 (R122) No. 8:
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit between ECM and fuel pump control unit Poor contact of coupling connector

Step CHECK HARNESS BETWEEN ECM AND FUEL PUMP CONTROL UNIT. Measure the resistance between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 9 Chassis ground: (R122) No. 8 Chassis ground: CHECK POOR CONTACT. Check for poor contact of ECM and fuel pump control unit connector. Check Is the resistance 1 M: or more? Yes Go to step 7. No Repair the ground short circuit of harness between ECM and fuel pump control unit.
Is there poor contact in ECM or Repair the poor fuel pump control unit connec- contact of ECM or tor? fuel pump control unit connector. CHECK EXPERIENCE OF RUNNING OUT OF Has the vehicle experienced Finish the diagnoFUEL. running out of fuel? sis. NOTE: DTC may be recorded as a result of fuel pump idling while running out of fuel.
Go to step 8.
Replace the fuel pump control unit. <Ref. to FU(H4DOTC)-56, Fuel Pump Control Unit.>

AP:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A RANGE/PERFORMANCE

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-76, DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 6 4 2 1 B47 BATTERY SBF-7 B47 1 3 5 2 4 6
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29
B137
ECM E64
27
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
B21 E2 48 50 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
E64 1 2 WASTEGATE CONTROL SOLENOID VALVE
EN-05674

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> No Replace the wastegate control solenoid valve. <Ref. to FU(H4DOTC)-45, Wastegate Control Solenoid Valve.>

AQ:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-78, DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29
B137
ECM E64
27
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
B21 E2 48 50 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05674

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 27 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND WASTEGATE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and wastegate control solenoid valve. 3) Measure the resistance between wastegate control solenoid valve connector and engine ground. Connector & terminal (E64) No. 2 Engine ground: CHECK HARNESS BETWEEN ECM AND WASTEGATE CONTROL SOLENOID VALVE. Measure the resistance of harness between ECM and wastegate control solenoid valve connector. Connector & terminal (B137) No. 27 (E64) No. 2: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair ground short circuit of harness between ECM and wastegate control solenoid valve connector.
CHECK WASTEGATE CONTROL SOLEIs the resistance between 10 NOID VALVE. 100 :? 1) Remove the wastegate control solenoid valve. 2) Measure the resistance between wastegate control solenoid valve terminals. Terminals No. 1 No. 2: CHECK POWER SUPPLY TO WASTEGATE Is the voltage 10 V or more? CONTROL SOLENOID VALVE. 1) Turn the ignition switch to ON. 2) Measure the voltage between wastegate control solenoid valve and engine ground. Connector & terminal (E64) No. 1 (+) Engine ground ():
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and wastegate control solenoid valve connector Poor contact of coupling connector Replace the wastegate control solenoid valve. <Ref. to FU(H4DOTC)-45, Wastegate Control Solenoid Valve.>
Repair poor contact in wastegate control solenoid valve connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between main relay and wastegate control solenoid valve connector Poor contact of coupling connector Poor contact of main relay connector

AR:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-79, DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29
B137
ECM E64
27
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
B21 E2 48 50 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05674

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? WASTEGATE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and wastegate control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 27 (+) Chassis ground (): CHECK WASTEGATE CONTROL SOLEIs the resistance less than 1 :? NOID VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between wastegate control solenoid valve terminals. Terminals No. 1 No. 2: Yes No Repair short cirGo to step 2. cuit of the harness to power supply between ECM and wastegate control solenoid valve connector.
Replace the waste- Repair the poor gate control sole- contact of ECM noid valve. <Ref. to connector. FU(H4DOTC)-45, Wastegate Control Solenoid Valve.>
AS:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4DOTC)(diag)-171, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>




DTC DETECTING CONDITION: Two consecutive driving cycles with fault Immediately at fault recognition (A misfire which could damage catalyst occurs.) GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-85, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling Rough driving CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
10
54
48
53
52
51 E6 2 #4 1
B21 E2
E5 2 1 1 2
E16 2 1
E17
#1
#2
#3
FUEL INJECTOR
E5 E16
E6 E17
B21
B47 1 3 5 2 4 6
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05668

Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector Replace the faulty fuel injector. <Ref. to FU(H4DOTC)38, Fuel Injector.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the main relay and fuel injector connector on faulty cylinders Poor contact of coupling connector Poor contact of main relay connector

Step CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. CHECK CRANK SPROCKET. Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET CHECK FUEL LEVEL. Check Is the voltage 10 V or more? Yes No Go to step 7. Repair the short circuit to power in the harness between the ECM and fuel injector.
Is the resistance less than 1 :? Replace the faulty Go to step 8. fuel injector. <Ref. to FU(H4DOTC)38, Fuel Injector.>
10
Is the camshaft position sensor Tighten the cam- Go to step 9. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 10. does it have broken teeth? sprocket. <Ref. to ME(H4DOTC)-57, Crank Sprocket.> Is the timing belt dislocated Repair the installa- Go to step 11. from its proper position? tion condition of timing belt. <Ref. to ME(H4DOTC)-47, Timing Belt.>
11
Is the fuel meter indication higher than the Lower level?
Go to step 12.
12
CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 14. CATOR LIGHT. light illuminate or blink? 1) Clear the memory using the Subaru Select Monitor or general scan tool. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> 2) Start the engine, and drive the vehicle 10 minutes or more.
Refill the fuel so that fuel meter indication is higher than the Lower level. After replenishing fuel, Go to step 12. Go to step 13.

13
14
15
16
17
18
19
CHECK MISFIRE SYMPTOM. 1) Turn the ignition switch to ON. 2) Read the DTC. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK DTC. Are DTC P0301 and P0302 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Are DTC P0303 and P0304 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Are DTC P0301 and P0303 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Are DTC P0302 and P0304 displayed on the Subaru Select Monitor or general scan tool?
Go to step 21.
Go to step 17.
Go to step 22.
Go to step 18.
Go to step 23.
Go to step 19.
Go to step 24.
Go to step 25.

Step ONLY ONE CYLINDER. Check Is there any fault in the cylinder? Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plug Spark plug cord Fuel injector Compression ratio Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Ignition coil Compression ratio If any fault is not found, check the IGNITION CONTROL SYSTEM of #1 and #2 cylinders side. <Ref. to EN(H4DOTC)(diag)-73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Ignition coil Compression ratio If any fault is not found, check the IGNITION CONTROL SYSTEM of #3 and #4 cylinders side. <Ref. to EN(H4DOTC)(diag)-73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> No Go to DTC P0171. <Ref. to EN(H4DOTC)(diag) -149, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to DTC P0171. <Ref. to EN(H4DOTC)(diag) -149, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
20
21
22
Go to DTC P0171. <Ref. to EN(H4DOTC)(diag) -149, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

Step GROUP OF #1 AND #3 CYLINDERS. Check Are there any faults in #1 and #3 cylinders? Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio Skipping timing belt teeth Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio Skipping timing belt teeth Go to DTC P0171. <Ref. to EN(H4DOTC)(diag) -149, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> No Go to DTC P0171. <Ref. to EN(H4DOTC)(diag) -149, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to DTC P0171. <Ref. to EN(H4DOTC)(diag) -149, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio
23
24
25
CYLINDER AT RANDOM.
Is the engine idle rough?

AW:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-86, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance Knocking occurs. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 E2 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 6 4
29
15
B134
ECM
25
EN-05675

Replace the knock sensor. <Ref. to FU(H4DOTC)-34, Knock Sensor.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and knock sensor Poor contact of the knock sensor connector Poor contact of coupling connector

AX:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-87, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance Knocking occurs. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 E2 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 6 4
29
15
B134
ECM
25
EN-05675

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 15 (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor connectors. Terminals No. 1 No. 2: Check Is the resistance less than 500 k:? Yes Go to step 2. No Go to step 3.
CHECK INPUT SIGNAL OF ECM. 1) Connect the ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 15 (+) Chassis ground ():
Replace the knock sensor. <Ref. to FU(H4DOTC)-34, Knock Sensor.>

AY:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-88, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E10 1 2
E10
B134 1 8 9 18 19 28 29 E2 14 3 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
14
13
B134 ECM
24
EN-05676

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened securely? CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 and 1) Turn the ignition switch to OFF. 4 k:? 2) Remove the crankshaft position sensor. 3) Measure the resistance between connector terminals of crankshaft position sensor. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? CRANK SHAFT POSITION SENSOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and crankshaft position sensor connector. Connector & terminal (B134) No. 13 (E10) No. 1: (B134) No. 14 (E10) No. 2: Yes Go to step 2. No Tighten the crankshaft position sensor installation bolt securely. Replace the crankshaft position sensor. <Ref. to FU(H4DOTC)-32, Crankshaft Position Sensor.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and crankshaft position sensor connector Poor contact of coupling connector
Go to step 3.

AZ:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-90, DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E10 1 2
E10
B134 1 8 9 18 19 28 29 E2 14 3 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
14
13
B134 ECM
24
EN-05676

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened Turn the ignition switch to OFF. securely? CHECK CRANK SPROCKET. Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET Are crank sprocket teeth cracked or damaged? No Tighten the crankshaft position sensor installation bolt securely. Replace the crank Go to step 3. sprocket. <Ref. to ME(H4DOTC)-57, Crank Sprocket.> Repair the installa- Replace the cranktion condition of shaft position sentiming belt. <Ref. to sor. <Ref. to ME(H4DOTC)-47, FU(H4DOTC)-32, Timing Belt.> Crankshaft Position Sensor.> Yes Go to step 2.
Is the timing belt dislocated from its proper position?

BA:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-92, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 SBF-7 6 4 2 1 B47 BATTERY
INTAKE CAMSHAFT POSITION SENSOR LH
INTAKE CAMSHAFT POSITION SENSOR RH
E
1 2 3 1 E35 2 3 E36
E2 48 13 2 B21 B134 ECM 21 11 5 B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 22
E35 E36
B47
B21
1 2 3
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05677

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 1 (+) Engine ground (): Yes Go to step 2. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and camshaft position sensor Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and camshaft position sensor.
CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between the ECM and camshaft position sensor connector. Connector & terminal (B134) No. 11 (E36) No. 2: (B134) No. 22 (E36) No. 3:
CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 2 Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 2 (+) Engine ground (): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.
Go to step 4.
Repair the short Go to step 5. circuit to power in harness between ECM and camshaft position sensor.
Is the camshaft position sensor Go to step 6. installation bolt tightened securely? Is there any abnormality in waveform?
CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor. <Ref. to EN(H4DOTC)(diag)-17, Engine Control Module (ECM) I/O Signal.>
Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. <Ref. to Poor contact in FU(H4DOTC)-33, ECM connector Camshaft Position Poor contact of camshaft position Sensor.> sensor connector Poor contact of coupling connector

BB:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-93, DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 SBF-7 6 4 2 1 B47 BATTERY
INTAKE CAMSHAFT POSITION SENSOR LH
INTAKE CAMSHAFT POSITION SENSOR RH
E
1 2 3 1 E35 2 3 E36
E2 48 13 2 B21 B134 ECM 21 11 5 B134 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 22
E35 E36
B47
B21
1 2 3
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05677

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E35) No. 1 (+) Engine ground (): Yes Go to step 2. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and camshaft position sensor Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and camshaft position sensor.
Go to step 4.
Repair the short Go to step 5. circuit to power in harness between ECM and camshaft position sensor.
CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor. <Ref. to EN(H4DOTC)(diag)-17, Engine Control Module (ECM) I/O Signal.>
Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. <Ref. to Poor contact in FU(H4DOTC)-33, ECM connector Camshaft Position Poor contact of camshaft position Sensor.> sensor connector Poor contact of coupling connector

BC:DTC P0410 SECONDARY AIR INJECTION SYSTEM

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-94, DTC P0410 SECONDARY AIR INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
MAIN RELAY B47 5 3 SBF-7 6 4 2 1 MAIN SBF BATTERY
E
F9 6 5 MAIN FUSE BOX (M/B) B143 9 2 14 12 10 4 F37 11 5 16 18 20 8 15 16 4 3 1 2 7 8 10 9 4 B21 E2 B144 14 F37 14 11 12 13 SECONDARY AIR PUMP RELAY 10A 60A SECONDARY AIR COMBINATION VALVE RELAY1 RELAY HOLDER
A: B134 C: B136
C30 C19 C8 A19 A27 A29
SECONDARY AIR COMBINATION VALVE RELAY2
ECM
6 1 28 47 46
F11 3 2 1 6 4 1 2 E41 E40 2 1 SECONDARY AIR PUMP
E
SECONDARY AIR COMBINATION VALVE RH (WITH BUILT-IN PRESSURE SENSOR) E40 F11 1 2 B47 E41 1 2 3 4 5 6 1 8 9 18 19 28 29 2 10 20 30 SECONDARY AIR COMBINATION VALVE LH B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK SECONDARY AIR PUMP FUSE. Check if the secondary air pump fuse (60 A) is blown out. CHECK HARNESS BETWEEN FUSE BOX AND SECONDARY AIR PUMP. 1) Remove the secondary air pump fuse from the fuse box. 2) Disconnect the secondary air pump connector. 3) Measure resistance between the secondary air pump fuse and secondary air pump connector, and chassis ground. Connector & terminal (F9) No. 16 Chassis ground: (F11) No. 2 Chassis ground: CHECK SECONDARY AIR PUMP OPERATION. 1) Connect the delivery (test) mode connector. 2) Turn the ignition switch to ON. 3) Perform the Clear Memory Mode. 4) Perform operation check for the secondary air pump using the Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to Clear Memory Mode<Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> and Compulsory Valve Operation Check Mode<Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.>. The compulsory operation using the Subaru Select Monitor is performed only for 5 seconds in order to protect the secondary air pump. When operating again, perform the Clear Memory Mode. CHECK DUCT BETWEEN SECONDARY AIR PUMP AND COMBINATION VALVE. Check the duct between the secondary air pump and combination valve. Check Is the fuse blown out? Yes Go to step 2. No Go to step 3.
Replace the fuse with a new part, and then connect the secondary air pump connector. Go to step 3.
Repair ground short of the harness between the fuse box and the secondary air pump.
Does the secondary air pump operate?
Go to step 4.
Go to step 5.
Is there damage, clog or disconnection of the duct?
Replace, clean or connect the duct.
CHECK POWER SUPPLY TO SECONDARY Is the voltage 10 V or more? AIR PUMP. 1) Perform the Clear Memory Mode. 2) Turn the ignition switch to OFF. 3) Disconnect the secondary air pump connector. 4) In the condition of step 3, measure the voltage between the secondary air pump connector and the chassis ground. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-52, Clear Memory Mode.> Connector & terminal (F11) No. 2 (+) Chassis ground ():
Replace the secondary air pump. <Ref. to EC(H4DOTC)-21, Secondary Air Pump.>
Replace the secondary air combination valve RH. <Ref. to EC(H4DOTC)-22, Secondary Air Combination Valve.> Go to step 6.

Step CHECK HARNESS BETWEEN SECONDARY AIR PUMP RELAY AND SECONDARY AIR PUMP CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the secondary air pump relay. 3) Measure the resistance between the secondary air pump relay and secondary air pump connector. Connector & terminal (F9) No. 11 (F11) No. 2: CHECK HARNESS BETWEEN SECONDARY AIR PUMP CONNECTOR AND CHASSIS GROUND. Measure the resistance of the harness between secondary air pump connector and chassis ground. Connector & terminal (F11) No. 1 Chassis ground: CHECK SECONDARY AIR PUMP RELAY. 1) Connect the battery to terminals No. 12 and No. 13 of the secondary air pump relay. 2) Measure the resistance between secondary air pump relay terminals. Terminals No. 14 No. 11: CHECK SECONDARY AIR PUMP RELAY POWER SOURCE. 1) Turn the ignition switch to ON. 2) Measure the voltage between the secondary air pump relay connector and chassis ground. Connector & terminal (F9) No. 14 (+) Chassis ground (): (F9) No. 12 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND SECONDARY AIR PUMP RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector of ECM. 3) Measure the resistance of harness between ECM and secondary air pump relay connector. Connector & terminal (B136) No. 8 (F9) No. 13: Check Yes Is the resistance less than 1 :? Go to step 7. No Repair the open circuit between secondary air pump relay and secondary air pump connector.
Repair the open circuit of the harness between secondary air pump connector and chassis ground.
Replace the secondary air pump relay. <Ref. to EN(H4DOTC)(diag) -8, Electrical Component Location.> Repair the open or ground short circuit of power supply circuit.
Go to step 10.
10
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and secondary air pump relay connector. Poor contact of coupling connector

BD:DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-101, DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step Check CHECK SECONDARY AIR COMBINATION Is there damage or disconnecVALVE. tion of the pipe? Check the pipe between the secondary air combination valve and cylinder head. CHECK SECONDARY AIR COMBINATION Is there any exhaust leak? VALVE. Race the engine at 2,000 rpm to check whether or not the exhaust leak is heard. Yes Replace the pipe between secondary air combination valve and cylinder head. Replace the pipe between secondary air combination valve and cylinder head. No Go to step 2.

BE:DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-102, DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. SECONDARY AIR COMBINATION VALVE RELAY 1. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and secondary air combination valve relay 1. 3) Measure the resistance of harness between ECM and secondary air combination valve relay 1. Connector & terminal (B136) No. 30 (F9) No. 2: CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 1. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 30 Chassis ground: Is the resistance 1 M: or more? No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and secondary air combination valve relay 1 Poor contact of coupling connector Even if DTC is Repair the ground detected, the cir- short circuit of harcuit has returned to ness between a normal condition ECM and secondat this time. Repro- ary air combination duce the failure, valve relay 1. and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

BF:DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-103, DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 1. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and secondary air combination valve relay 1. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 30 (+) Chassis ground (): Check Is the voltage 10 V or more? Yes No Repair the short Repair the poor circuit to power in contact of ECM the harness connector. between ECM and secondary air combination valve relay 1.

BG:DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-103, DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. SECONDARY AIR COMBINATION VALVE RELAY 2. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and secondary air combination valve relay 2. 3) Measure the resistance of harness between ECM and secondary air combination valve relay 2. Connector & terminal (B136) No. 19 (F9) No. 9: CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 2. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 Chassis ground: Is the resistance 1 M: or more? No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and secondary air combination valve relay 2 Poor contact of coupling connector Even if DTC is Repair the ground detected, the cir- short circuit of harcuit has returned to ness between a normal condition ECM and secondat this time. Repro- ary air combination duce the failure, valve relay 2. and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

BH:DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT SHORTED
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-103, DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 2. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and secondary air combination valve relay 2. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 19 (+) Chassis ground (): Check Is the voltage 10 V or more? Yes No Repair the short Repair the poor circuit to power in contact of ECM the harness connector. between ECM and secondary air combination valve relay 2.

BI: DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT OPEN
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-104, DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK HARNESS BETWEEN ECM AND SECONDARY AIR PUMP RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the ECM and secondary air pump relay. 3) Measure the resistance of the harness between the ECM and secondary air pump relay. Connector & terminal (B136) No. 8 (F9) No. 13: CHECK HARNESS BETWEEN ECM AND SECONDARY AIR PUMP RELAY. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 8 Chassis ground: Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and secondary air pump relay Poor contact of coupling connector Even if DTC is Repair ground detected, the cir- short circuit of the cuit has returned to harness between a normal condition the ECM and secat this time. Repro- ondary air pump duce the failure, relay. and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-105, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 * *
B30 C4 B4 B1 2 2
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670

Yes Repair or replace the exhaust system. <Ref. to EX(H4DOTC)-2, General Description.>
No Go to step 2.
EN-06666

0.5 10 sec/div
EN-06667

1
0 10 sec/div
EN-06668

1
0 10 sec/div
EN-06669

1
0 10 sec/div
EN-06670
Is the catalytic converter dam- Replace the cataaged? lytic converter. <Ref. to EC(H4DOTC)-5, Front Catalytic Converter.> CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside.
Go to step 5.
Go to step 6.

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 7. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (T6) No. 3: (B135) No. 30 (T6) No. 4: No Repair the harness and connector. NOTE: Repair the following locations. Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: Repair the following locations. Open circuit of harness between the ECM and rear oxygen sensor Poor contact in ECM and rear oxygen sensor Poor contact in ECM connector Repair the open circuit in the rear oxygen sensor harness.
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (T6) No. 3 (+) Chassis ground ():
Go to step 8.
Replace the rear oxygen sensor. <Ref. to FU(H4DOTC)-48, Rear Oxygen Sensor.>

BK:DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-107, DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> CHECK PURGE LINE OF THE PURGE CON- Is there any clogging, flattened Repair or replace TROL SOLENOID VALVE 2. part or bent in the purge line of the purge line of purge control solenoid valve 2? purge control solenoid valve 2. CHECK PURGE CONTROL SOLENOID Does the purge control soleRepair the poor VALVE 2. noid valve 2 operate? contact of ECM 1) Connect the delivery (test) mode connector. connector. 2) Turn the ignition switch to ON. 3) Operate the purge control solenoid valve 2 using the Subaru Select Monitor. NOTE: Purge control solenoid valve 2 can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? No Go to step 2.
Go to step 3.
Replace the purge control solenoid valve 2. <Ref. to EC(H4DOTC)-9, Purge Control Solenoid Valve.>

BL:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-108, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY SBF-7 5 3 6 4 2 1 B47 C17 C28 D29 C7 BATTERY
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
PRESSURE CONTROL SOLENOID VALVE B97 R67 1 2 3 4 5 6
PURGE CONTROL PURGE CONTROL SOLENOID VALVE 1 SOLENOID VALVE 2
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H4DOTC)-66, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H4DOTC)-19, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: The drain valve can be operated using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H4DOTC)-9, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H4DOTC)-16, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 1.0 mm (0.04 in) dia. on evapo- the evaporation 1) Turn the ignition switch to OFF. ration line? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H4DOTC)-80, tor. Fuel Delivery, Return and Evaporation Lines.>

Step CHECK CANISTER. Yes Repair or replace the canister. <Ref. to EC(H4DOTC)-7, Canister.> Is the fuel tank damaged or is Repair or replace there any hole of more than 1.0 the fuel tank. <Ref. to FU(H4DOTC)mm (0.04 in) dia. in it? 59, Fuel Tank.> Is there any hole of more than Repair or replace 1.0 mm (0.04 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system? Check Is the canister damaged or is there a hole of more than 1.0 mm (0.04 in) dia. in it? No Go to step 9.
CHECK FUEL TANK. Remove the fuel tank. <Ref. to FU(H4DOTC)59, Fuel Tank.> CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.
Go to step 10.
10

BM:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-124, DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-05679

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 17 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Measure the resistance between the drain valve connector and chassis ground. Connector & terminal (R144) No. 2 Chassis ground: CHECK HARNESS BETWEEN ECM AND DRAIN VALVE. Measure the resistance of harness between ECM and drain valve connector. Connector & terminal (B136) No. 17 (R144) No. 2: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and drain valve connector Poor contact of coupling connector Replace the drain valve. <Ref. to EC(H4DOTC)-19, Drain Valve.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between main relay and drain valve Poor contact of coupling connector Poor contact of main relay connector

BN:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-126, DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-05679

Replace the drain Repair the poor valve. <Ref. to contact of ECM EC(H4DOTC)-19, connector. Drain Valve.>

BO:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-128, DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* * *
B83
22
32
B135 ECM
30
R47
R213 1 2 3 4 5 6 7 8
B83
1 2 3 4 5 6 7 8
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3
EN-05095

Step CHECK FUEL FILLER CAP. 1) Turn the ignition switch to OFF. 2) Open the fuel flap. CHECK PRESSURE VACUUM LINE. NOTE: Check the following items. Disconnection, leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank Disconnection, leakage and clogging of the air ventilation hoses and pipes between fuel filler pipe and fuel tank Check Is the fuel filler cap tightened securely? Is there any fault in pressure/ vacuum line? Yes Go to step 2. No Tighten fuel filler cap securely. Replace the fuel tank pressure sensor. <Ref. to EC(H4DOTC)-15, Fuel Tank Pressure Sensor.>

BP:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-130, DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* * *
B83
22
32
B135 ECM
30
R47
R213 1 2 3 4 5 6 7 8
B83
1 2 3 4 5 6 7 8
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3
EN-05095

Step CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK FUEL TANK PRESSURE SENSOR POWER SOURCE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the fuel tank pressure sensor connector and chassis ground. Connector & terminal (R47) No. 3 (+) Chassis ground (): Check Yes Is the measured value less than Go to step 2. 7.45 kPa (55.89 mmHg, 2.2003 inHg) ? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact in ECM connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel tank pressure sensor connector. Replace the fuel tank pressure sensor. <Ref. to EC(H4DOTC)-15, Fuel Tank Pressure Sensor.>
Go to step 3.
Go to step 5.

BQ:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-132, DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* * *
B83
22
32
B135 ECM
30
R47
R213 1 2 3 4 5 6 7 8
B83
1 2 3 4 5 6 7 8
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3
EN-05095

Step CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel tank pressure sensor connector and engine ground. Connector & terminal (R47) No. 1 Engine ground: Check Yes Is the measured value 7.98 kPa Go to step 2. (59.86 mmHg, 2.357 inHg) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is the measured value 7.98 kPa Repair the short (59.86 mmHg, 2.357 inHg) or circuit to power more? supply in the harness between the ECM and fuel tank pressure sensor connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact in ECM connector Poor contact of coupling connector CHECK POOR CONTACT. Is there poor contact in fuel tank Repair the poor Replace the fuel Check for poor contact of the fuel tank pressure pressure sensor connector? contact in the fuel tank pressure sensensor connector. tank pressure sensor. <Ref. to EC(H4DOTC)-15, sor connector. Fuel Tank Pressure Sensor.>

BR:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-133, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H4DOTC)-66, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H4DOTC)-19, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H4DOTC)-9, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H4DOTC)-16, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 0.5 mm (0.020 in) dia. on evap- the evaporation 1) Turn the ignition switch to OFF. oration line? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H4DOTC)-80, tor. Fuel Delivery, Return and Evaporation Lines.>

Step CHECK CANISTER. Check Yes Is the canister damaged or is Repair or replace there a hole of more than 0.5 mm the canister. <Ref. (0.020 in) dia. in it? to EC(H4DOTC)-7, Canister.> Is the fuel tank damaged or is Repair or replace there any hole of more than the fuel tank. <Ref. to FU(H4DOTC)0.5 mm (0.020 in) dia. in it? 59, Fuel Tank.> Is there any hole of more than Repair or replace 0.5 mm (0.020 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system? No Go to step 9.
Go to step 10.
10

BS:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-133, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor Fuel filler cap loose or lost CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H4DOTC)-66, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H4DOTC)-19, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H4DOTC)-9, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H4DOTC)-16, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONAre there any disconnected, Repair or replace Go to step 8. TROL SYSTEM LINE. broken or clogged evaporation the evaporation 1) Turn the ignition switch to OFF. lines? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H4DOTC)-80, tor. Fuel Delivery, Return and Evaporation Lines.>

Step CHECK CANISTER. Check Is the canister damaged? Yes Repair or replace the canister. <Ref. to EC(H4DOTC)-7, Canister.> Repair or replace the fuel tank. <Ref. to FU(H4DOTC)59, Fuel Tank.> Repair or replace the hoses or pipes. No Go to step 9.
Go to step 10.
10

BT:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-134, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground (): OPEN CIRCUIT IN HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Measure the resistance between the purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 2 Engine ground: OPEN CIRCUIT IN HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE. Measure the resistance of harness between ECM and purge control solenoid valve connector. Connector & terminal (B137) No. 29 (E4) No. 2: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and purge control solenoid valve connector Poor contact of coupling connector Replace the purge control solenoid valve. <Ref. to EC(H4DOTC)-9, Purge Control Solenoid Valve.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and purge control solenoid valve connector Poor contact of coupling connector Poor contact of main relay connector

BU:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-136, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Step Check OPEN CIRCUIT IN HARNESS BETWEEN Is the voltage 10 V or more? ECM AND PURGE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground (): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 :? VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 No. 2: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and purge control solenoid valve connector.
Replace the purge Repair the poor control solenoid contact of ECM valve. <Ref. to connector. EC(H4DOTC)-9, Purge Control Solenoid Valve.>

BV:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-138, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> No Replace the fuel level sensor and fuel sub level sensor. <Ref. to FU(H4DOTC)-72, Fuel Level Sensor.> <Ref. to FU(H4DOTC)-73, Fuel Sub Level Sensor.>
BW:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

NOTE: For the diagnostic procedure, refer to DTC P0463. <Ref. to EN(H4DOTC)(diag)-239, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BX:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-142, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0462 or P0463 displayed on the Subaru Select Monitor? Yes Check the combination meter. <Ref. to IDI-13, CHECK FUEL LEVEL SENSOR, INSPECTION, Combination Meter System.> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

BY:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-144, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step Check Yes CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0464 displayed on the Check the combidisplay? nation meter. <Ref. to IDI-13, CHECK FUEL LEVEL SENSOR, INSPECTION, Combination Meter System.> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
BZ:DTC P0500 VEHICLE SPEED SENSOR A

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-147, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step CHECK DTC OF ABS OR VDC. Check DTC of ABS or VDC. Check Is DTC of ABS or VDC displayed? Yes No Perform the diag- Repair the poor nosis according to contact of ECM DTC. <Ref. to connector. ABS(diag)-29, List of Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>

CA:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-148, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start the engine. Engine does not start. Improper idling Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31
EN-05673

Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> CHECK AIR CLEANER ELEMENT. Is the air cleaner element Replace the air 1) Turn the ignition switch to OFF. excessively clogged? cleaner element. 2) Check the air cleaner element. <Ref. to IN(H4DOTC)-7, Air Cleaner Element.> CHECK ELECTRONIC THROTTLE CONAre foreign matter found inside Remove foreign electronic throttle control? matter from elecTROL. 1) Remove the electronic throttle control. <Ref. tronic throttle control. to FU(H4DOTC)-14, REMOVAL, Throttle Body.> 2) Check the electronic throttle control. Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? No Go to step 2.
Go to step 3.
Perform the diagnosis of DTC P2101. <Ref. to EN(H4DOTC)(diag) -318, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

CB:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-149, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05673

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> Repair air suction Go to step 3. and leaks.
CHECK AIR INTAKE SYSTEM. 1) Start and idle the engine. 2) Check the following items. Loose installation of intake manifold and throttle body Cracks of intake manifold gasket and throttle body gasket Disconnection of vacuum hoses CHECK ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control. <Ref. to FU(H4DOTC)-14, REMOVAL, Throttle Body.> 3) Check the electronic throttle control.
Perform the diagnosis of DTC P2101. <Ref. to EN(H4DOTC)(diag) -318, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

CC:DTC P0512 STARTER REQUEST CIRCUIT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-150, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
IGNITION SWITCH B72 BATTERY SBF-6 3 2 No. 21 MAIN SBF
MT AT
E
11 15 CLUTCH START SWITCH B106 10 2 7 13 9 1
INHIBITOR RELAY B226
STARTER RELAY B225 16 14
STARTER MOTOR
AT
MT B14
31
11
TCM B55
ECM B136
B106 1 2 B226 1 2 3 4 7 8 9 10 11 5 6
32
20
B72 1 2 3 4 5 6 B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28
B225 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
EN-06951

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> Repair the short circuit to power in the harness between the ECM and ignition switch. No Go to step 2.
CD:DTC P0600 SERIAL COMMUNICATION LINK


CE:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-154, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine does not start. Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B72
BATTERY
34 35 36 37 40
B21 E2
B72
B47 1 3 5 2 4 6
B21
A: 1 8 9 18 19 28 29 2 10 20 30
B134
B:
B135
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-05666

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
CF:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
NOTE: For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4DOTC)(diag)-249, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

CG:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-156, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 3 5 6 4 2 1 B47 No.12 1 C23 B2 A7 B5 B19 3 IGNITION SWITCH SBF-6 MAIN SBF TO OXYGEN SENSOR SBF-5 SBF-7 No.13 B72 BATTERY
ECM A: B134 D3 D2 D1 D7 A5 B: B135 C: B136 D: B137 A28 A18
A19 D4 D5 A29
B122
C6
* *
37 35 34 40 36 24 E2 28 39 38 6 25 B21
*
5 1 2 3 4 6
B72 1 2 3 4 5 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B21
E57
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 C:
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 1 8 9 20 21 28 29
B: B135
2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 19 24 25 26 27 22 23 34 35 30 31 32 33
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29
EN-05681

Step CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. 1) Start the engine. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 19 (E57) No. 5: (B134) No. 29 (E57) No. 3: CHECK ECM GROUND HARNESS. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 5 (+) Chassis ground (): (B137) No. 1 (+) Chassis ground (): (B137) No. 2 (+) Chassis ground (): (B137) No. 3 (+) Chassis ground (): (B137) No. 7 (+) Chassis ground (): Check Is the voltage 10 13 V? Yes Go to step 2. No Repair the open or ground short circuit of power supply circuit.
Is the voltage 13 15 V?
Go to step 3.
Repair the open circuit of harness between ECM and electronic throttle control connector.
Is the voltage less than 1 V?
Repair the following item. Open circuit of ground circuit Retightening of engine ground terminals Poor contact of coupling connector
CH:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)

NOTE: For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4DOTC)(diag)-318, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CI: DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

CJ:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)


CK:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-163, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B136
ECM
31
B136 B55 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
AT MT
11
TCM
B122
B128
1 2 3 4
MT
B128 3 1 T9
B122
1 2 3 4 5 6 7 8
T12 T12 2 1 T2 AT
: TERMINAL No. OPTIONAL ARRANGEMENT : AT MODEL
1 2
MT : MT MODEL
NEUTRAL POSITION SWITCH
EN-07063

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage 10 V or more? 1) Turn the ignition switch to ON. 2) Place the shift lever in a position other than neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or NEUTRAL POSITION SWITCH CONNECmore? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect connectors from the ECM and transmission harness connector (T9). 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 31 Chassis ground: Yes Repair the poor contact of ECM connector. No Go to step 2.
Repair the short circuit of transmission harness or replace neutral position switch. <Ref. to 5MT-35, Switches and Harness.> <Ref. to 6MT-41, Neutral Position Switch.>
CL:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)


CM:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-165, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B136
ECM
31
B136 B55 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
AT MT
11
TCM
B122
B128
1 2 3 4
MT
B128 3 1 T9
B122
1 2 3 4 5 6 7 8
T12 T12 2 1 T2 AT
: TERMINAL No. OPTIONAL ARRANGEMENT : AT MODEL
1 2
MT : MT MODEL
NEUTRAL POSITION SWITCH
EN-07063

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage less than 1 V? 1) Turn the ignition switch to ON. 2) Place the shift lever in neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? NEUTRAL POSITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and transmission harness connector (T9). 3) Measure the resistance of harness between ECM and transmission harness connector. Connector & terminal (B136) No. 31 (B128) No. 1: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? NEUTRAL POSITION SWITCH CONNECTOR. Measure the resistance of harness between ECM and transmission harness connector. Connector & terminal (B128) No. 3 (B136) No. 6: Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair the open circuit in harness between ECM and transmission harness connector.
Go to step 4.
CHECK NEUTRAL POSITION SWITCH. Is the resistance less than 1 :? 1) Place the shift lever in neutral. 2) Measure the resistance between transmission harness connector terminals. Connector & terminal (T9) No. 1 No. 3:
Repair the poor contact of transmission harness connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and transmission harness connector Poor contact of coupling connector Repair the open circuit of transmission harness or replace the neutral position switch. <Ref. to 5MT-35, Switches and Harness.> <Ref. to 6MT-41, Neutral Position Switch.>

CN:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-166, DTC P1152 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669

Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Repair the poor Replace the front contact of the front oxygen (A/F) senoxygen (A/F) sensor. <Ref. to sor connector. FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.>

CO:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-168, DTC P1153 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669

Go to step 5.
Go to step 4.
Repair the short circuit to power in the harness between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).>
Replace the front oxygen (A/F) sensor. <Ref. to FU(H4DOTC)-46, Front Oxygen (A/F) Sensor.> Repair the poor contact of ECM connector.
CP:DTC P1160 RETURN SPRING FAILURE


CQ:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-172, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-05679

Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and pressure control solenoid valve connector Poor contact of coupling connector Replace the presCHECK PRESSURE CONTROL SOLENOID Is the resistance between 10 Go to step 5. 100 :? sure control soleVALVE. noid valve. <Ref. to Measure the resistance between pressure conEC(H4DOTC)-16, trol solenoid valve terminals. Pressure Control Terminals Solenoid Valve.> No. 1 No. 2: CHECK POWER SUPPLY TO THE PRESIs the voltage 10 V or more? Repair the poor Repair the harness SURE CONTROL SOLENOID VALVE. contact of pressure and connector. 1) Turn the ignition switch to ON. control solenoid NOTE: 2) Measure the voltage between pressure convalve connector. In this case, repair trol solenoid valve and chassis ground. the following item: Connector & terminal Open circuit in (R68) No. 1 (+) Chassis ground (): harness between main relay and pressure control solenoid valve connector Poor contact of coupling connector Poor contact of main relay connector

CR:DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-174, DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step Check CHECK SECONDARY AIR COMBINATION Are there air leaks from the pipe VALVE. connections? 1) Remove the secondary air combination valve. <Ref. to EC(H4DOTC)-22, Secondary Air Combination Valve.> 2) Blow air from the secondary air combination valve air inlet, and check whether there are leaks at the pipe connections. Yes Replace the secondary air combination valve on the side with the air leak. <Ref. to EC(H4DOTC)-22, Secondary Air Combination Valve.> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

CS:DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-176, DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK HARNESS BETWEEN ECM AND SECONDARY AIR PUMP RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the ECM and secondary air pump relay. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 8 (+) Chassis ground (): Check Is the voltage 10 V or more? Yes Repair short circuit of the harness to power supply between the ECM and secondary air pump relay. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

CT:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-177, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Is the resistance less than 1 :? Replace the pres- Repair the poor sure control sole- contact of ECM noid valve. <Ref. to connector. EC(H4DOTC)-16, Pressure Control Solenoid Valve.>

CU:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-179, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper fuel supply CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> Replace the drain hose. Repair the poor contact of ECM connector. No Go to step 2.
2 3
CHECK DRAIN HOSE. Is there clogging in the drain Check the drain hose for clogging. hose? CHECK DRAIN VALVE OPERATION. Does the drain valve operate? 1) Turn the ignition switch to OFF. 2) Connect the delivery (test) mode connector at the lower portion of instrument panel (on the drivers side). 3) Turn the ignition switch to ON. 4) Operate the drain valve. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.>
Go to step 3. Replace the drain valve. <Ref. to EC(H4DOTC)-19, Drain Valve.>

CV:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-181, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
A: B134 ECM D: B137
A30 D6
D26
A: B134 1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
D: B137 B21 E2 45 41 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
E80 1 2
PCV HOSE ASSY
2 1 E80
EN-05683

Step Check Yes CHECK BLOW-BY HOSE. Is there any disconnection or Repair or replace Check the condition of the blow-by hose. crack in blow-by hose? the blow-by hose. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 3. PCV HOSE ASSEMBLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and PCV hose assembly. 3) Measure the resistance of harness between ECM and PCV hose assembly. Connector & terminal (B134) No. 30 (E80) No. 2: No Go to step 2. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and PCV hose assembly Poor contact of coupling connector Repair the ground short circuit of harness between ECM and PCV hose assembly. Repair the open circuit of harness between PCV hose assembly and engine ground.
1 2
CHECK HARNESS BETWEEN ECM AND PCV HOSE ASSEMBLY. Measure the resistance between PCV hose assembly and chassis ground. Connector & terminal (B134) No. 30 Chassis ground: CHECK GROUND CIRCUIT OF PCV HOSE ASSEMBLY. Measure the resistance of harness between PCV hose assembly and engine ground. Connector & terminal (E80) No. 1 Engine ground: CHECK THE PCV HOSE ASSEMBLY. Measure the resistance between the PCV hose assembly terminals. Terminals No. 1 No. 2:
Go to step 4.
Is the resistance less than 1 :? Repair the poor Replace the PCV contact in ECM hose assembly. and PCV hose assembly connector.

CW:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-183, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B72
BATTERY
34 35 36 37 40
B21 E2
B72
B47 1 3 5 2 4 6
B21
A: 1 8 9 18 19 28 29 2 10 20 30
B134
B:
B135
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-05666

Step CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 5 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 5 Chassis ground: CHECK FUSE NO. 13. Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Replace the fuse.

CX:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-185, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. Engine keeps running at a lower speed than the specified idle speed. Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
10
54
48
53
52
51 E6 2 #4 1
B21 E2
E5 2 1 1 2
E16 2 1
E17
#1
#2
#3
FUEL INJECTOR
E5 E16
E6 E17
B21
B47 1 3 5 2 4 6
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EN-05668

4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05673

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> Go to step 3. Replace engine oil. <Ref. to LU(H4SO)-10, REPLACEMENT, Engine Oil.> Repair the exhaust Go to step 4. system. Repair the air Go to step 5. intake system. Repair the following item. Fuel pressure is too high: Clogged fuel return line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel supply line
CHECK ENGINE OIL.
3 4
Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 284 Go to step 6. 314 kPa (2.9 3.2 kg/cm2, WARNING: Place NO OPEN FLAMES signs near the 41 46 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. <Ref. to ME(H4DOTC)-25, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze the fuel return hose 2 to 3 times, then measure fuel pressure again. CHECK FUEL PRESSURE. Is the measured value 230 Go to step 7. After connecting the pressure regulator vacuum 260 kPa (2.35 2.65 kg/cm2, 33 38 psi)? hose, measure fuel pressure. <Ref. to ME(H4DOTC)-25, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. If the measured value at this step is out of specification, check or replace pressure regulator and pressure regulator vacuum hose.
Repair the following item. Fuel pressure is too high: Faulty pressure regulator Clogged fuel return line or bent hose Fuel pressure is too low: Faulty pressure regulator Improper fuel pump discharge Clogged fuel supply line

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 70C (158F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 70C (158F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Check Yes Is the engine coolant tempera- Go to step 8. ture 75C (167F) or higher? No Replace the engine coolant temperature sensor. <Ref. to FU(H4DOTC)-31, Engine Coolant Temperature Sensor.>
Is the measured value 2.0 5.0 g/s (0.26 0.66 lb/m)?
Go to step 9.

10
11
Go to step 12.
12
13
14
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector Replace the faulty fuel injector. <Ref. to FU(H4DOTC)38, Fuel Injector.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and fuel injector connector on faulty cylinders Poor contact of coupling connector Poor contact of main relay connector

Step CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. Check Is the voltage 10 V or more? Yes No Go to step 16. Repair the short circuit to power in the harness between the ECM and fuel injector.
15
16
Is the resistance less than 1 :? Replace the faulty Go to step 17. fuel injector. <Ref. to FU(H4DOTC)38, Fuel Injector.>
17
18
19
20
21
22
CHECK CRANK SPROCKET. Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.> CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET CHECK ELECTRONIC THROTTLE CONIs the resistance less than 1 :? TROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK POWER SUPPLY OF ELECTRONIC Is the voltage 10 V or more? THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (E362) No. 7 (+) Chassis ground (): Is the voltage 10 V or more? CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground ():
Is the camshaft position sensor Tighten the cam- Go to step 18. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 19. does it have broken teeth? sprocket. <Ref. to ME(H4DOTC)-57, Crank Sprocket.> Is the timing belt dislocated Repair the installa- Go to step 20. from its proper position? tion condition of timing belt. <Ref. to ME(H4DOTC)-47, Timing Belt.>
Go to step 21.
Replace the electronic throttle control relay. <Ref. to FU(H4DOTC)-55, Electronic Throttle Control Relay.>
Go to step 22.

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 8 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 8: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 24. No Repair the ground short circuit of harness between ECM and electronic throttle control relay.
23
24
Repair the open circuit of harness between ECM and electronic throttle control relay.
25
Go to step 26.
26
Go to step 27.
27
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).> Repair the open circuit of harness between ECM and electronic throttle control connector.

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? Go to step 29. ELECTRONIC THROTTLE CONTROL. 1) Connect the ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 Engine ground: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 30.
28
29
30
31
32
CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) Engine ground (): (E57) No. 4 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 (B134) No. 18: (B134) No. 19 (B134) No. 28: CHECK SENSOR OUTPUT. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> CHECK SENSOR OUTPUT. Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.>
Go to step 31.
Go to step 32.
Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4DOTC)-14, Throttle Body.> Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4DOTC)-14, Throttle Body.>
Go to step 33.

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 34. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B137) No. 5 (E57) No. 2: (B137) No. 4 (E57) No. 1: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) Engine ground (): (E57) No. 1 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 Engine ground: (E57) No. 1 Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between the electronic throttle control connector terminals. Connector & terminal (E57) No. 2 (E57) No. 1: CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 1 No. 2: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers. Is the voltage 5 V or more? Repair the short circuit to power in the harness between ECM and electronic throttle control. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control Poor contact of coupling connector Go to step 35.
33
34
35
Go to step 36.
36
Go to step 37.
Repair the short circuit of harness between ECM and electronic throttle control. Repair the open circuit in harness between ECM and engine ground.
37
38
Replace the electronic throttle control. <Ref. to FU(H4DOTC)-14, Throttle Body.> Replace the electronic throttle control. <Ref. to FU(H4DOTC)-14, Throttle Body.>
39

CY:DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-187, DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> CHECK TUMBLE GENERATOR VALVE RH. Is there any dirt or clogging with Clean the tumble Replace the tum1) Remove the tumble generator valve assem- foreign objects in the tumble generator valve. ble generator valve bly RH. generator valve? assembly RH. 2) Check the tumble generator valve body. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.> Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?
CZ:DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-188, DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> CHECK TUMBLE GENERATOR VALVE LH. Is there any dirt or clogging with Clean the tumble Replace the tum1) Remove the tumble generator valve assem- foreign objects in the tumble generator valve. ble generator valve bly LH. generator valve? assembly LH. 2) Check the tumble generator valve body. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.>

DA:DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-189, DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> CHECK TUMBLE GENERATOR VALVE RH. Is there any dirt or clogging with Clean the tumble Replace the tum1) Remove the tumble generator valve assem- foreign objects in the tumble generator valve. ble generator valve bly RH. generator valve? assembly RH. 2) Check the tumble generator valve body. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.> Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

DB:DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-190, DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.
1 Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> CHECK TUMBLE GENERATOR VALVE LH. Is there any dirt or clogging with Clean the tumble Replace the tum1) Remove the tumble generator valve assem- foreign objects in the tumble generator valve. ble generator valve bly LH. generator valve? assembly LH. 2) Check the tumble generator valve body. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.> Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

DC:DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-191, DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY RH (WITH BUILT-IN SENSOR)
4 19 ECM 23
E55
E2 8 B21
22 B137
E55 1 2 3 4 5
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05684

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and tumble generator valve assembly RH. 3) Measure the resistance of harness between ECM and tumble generator valve assembly RH. Connector & terminal (B137) No. 22 (E55) No. 5: (B137) No. 23 (E55) No. 4: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly RH connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and tumble generator valve assembly RH connector. Replace the tumble generator valve assembly RH. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.>
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 22 Chassis ground: (B137) No. 23 Chassis ground: CHECK POOR CONTACT. Check for poor contact of tumble generator valve assembly RH connector.
Go to step 3.
Is there poor contact in the tum- Repair the poor ble generator valve assembly contact of tumble RH connector? generator valve assembly RH connector.

DD:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-192, DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY RH (WITH BUILT-IN SENSOR)
4 19 ECM 23
E55
E2 8 B21
22 B137
E55 1 2 3 4 5
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05684

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 22 (+) Chassis ground (): (B137) No. 23 (+) Chassis ground (): Yes Repair the short circuit to power in the harness between ECM and tumble generator valve assembly RH. No Replace the tumble generator valve assembly RH. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.>

DE:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-193, DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY LH (WITH BUILT-IN SENSOR)
4 30 13
E51
E2 29 B21
12
B137 ECM
E51 1 2 3 4 5
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05685

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and tumble generator valve assembly LH. 3) Measure the resistance of harness between ECM and tumble generator valve assembly LH. Connector & terminal (B137) No. 12 (E51) No. 5: (B137) No. 13 (E51) No. 4: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly LH connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and tumble generator valve assembly LH connector. Replace the tumble generator valve assembly LH. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.>
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 12 Chassis ground: (B137) No. 13 Chassis ground: CHECK POOR CONTACT. Check for poor contact of tumble generator valve assembly LH connector.
Go to step 3.
Is there poor contact in the tum- Repair the poor ble generator valve assembly contact of tumble LH connector? generator valve assembly LH connector.

DF:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-194, DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY LH (WITH BUILT-IN SENSOR)
4 30 13
E51
E2 29 B21
12
B137 ECM
E51 1 2 3 4 5
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
EN-05685

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 12 (+) Chassis ground (): (B137) No. 13 (+) Chassis ground (): Yes Repair the short circuit to power in the harness between ECM and tumble generator valve assembly LH. No Replace the tumble generator valve assembly LH. <Ref. to FU(H4DOTC)-41, Tumble Generator Valve Assembly.>

DG:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-195, DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY RH (WITH BUILT-IN SENSOR) POSITION SENSOR E55 1 2 3 4 5
3 1 2 E55 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 28 16 6 B134 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
19 26 29
EN-05686

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (RH) using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF TUMBLE GEN- Is the voltage 4.5 V or more? Go to step 3. ERATOR VALVE ASSEMBLY RH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly RH. 3) Turn the ignition switch to ON. 4) Measure the voltage between tumble generator valve assembly RH connector and engine ground. Connector & terminal (E55) No. 3 (+) Engine ground (): No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly RH connector Poor contact in ECM connector Poor contact of coupling connector Is the resistance less than 1 :? Go to step 4. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly RH connector Poor contact of coupling connector Is the resistance 1 M: or Go to step 5. Repair the short more? circuit to ground in harness between ECM and tumble generator valve assembly RH connector. Is there poor contact in ECM or Repair the poor Replace the tumthe tumble generator valve contact in ECM or ble generator valve assembly RH connector? tumble generator assembly RH. valve assembly RH <Ref. to FU(H4DOTC)-41, connector. Tumble Generator Valve Assembly.>
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and tumble generator valve assembly RH. Connector & terminal (B134) No. 26 (E55) No. 1:
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 26 Chassis ground: CHECK POOR CONTACT. Check for poor contact of tumble generator valve assembly RH connector.

DH:DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-196, DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY RH (WITH BUILT-IN SENSOR) POSITION SENSOR E55 1 2 3 4 5
3 1 2 E55 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 28 16 6 B134 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
19 26 29
EN-05686

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (RH) using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly RH. 3) Start the engine. 4) Read the data of tumble generator valve position sensor signal (RH) using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between tumble generator valve assembly RH connector and engine ground. Connector & terminal (E55) No. 2 Engine ground: Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair the short circuit to power in harness between ECM and tumble generator valve assembly RH connector.
CHECK POOR CONTACT. Check for poor contact of tumble generator valve assembly RH connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly RH connector Poor contact in ECM connector Poor contact of coupling connector Is there poor contact in the tum- Repair the poor Replace the tumble generator valve assembly contact of tumble ble generator valve RH connector? generator valve assembly RH. assembly RH con- <Ref. to nector. FU(H4DOTC)-41, Tumble Generator Valve Assembly.>
Go to step 4.

DI: DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-197, DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY LH (WITH BUILT-IN SENSOR) POSITION SENSOR E51 1 2 3 4 5
3 1 2 E51 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 28 27 6 B134 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
19 16 29
EN-05687

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (LH) using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF TUMBLE GEN- Is the voltage 4.5 V or more? Go to step 3. ERATOR VALVE ASSEMBLY LH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly LH. 3) Turn the ignition switch to ON. 4) Measure the voltage between tumble generator valve assembly LH connector and engine ground. Connector & terminal (E51) No. 3 (+) Engine ground (): No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly LH connector Poor contact in ECM connector Poor contact of coupling connector Is the resistance less than 1 :? Go to step 4. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly LH connector Poor contact of coupling connector Is the resistance 1 M: or Go to step 5. Repair the short more? circuit to ground in harness between ECM and tumble generator valve assembly LH connector. Is there poor contact in ECM or Repair the poor Replace the tumthe tumble generator valve contact in ECM or ble generator valve assembly LH connector? tumble generator assembly LH. valve assembly LH <Ref. to FU(H4DOTC)-41, connector. Tumble Generator Valve Assembly.>
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and tumble generator valve assembly LH. Connector & terminal (B134) No. 16 (E51) No. 1:
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 16 Chassis ground: CHECK POOR CONTACT. Check for poor contact of tumble generator valve assembly LH connector.

DJ:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-198, DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
TUMBLE GENERATOR VALVE ASSY LH (WITH BUILT-IN SENSOR) POSITION SENSOR E51 1 2 3 4 5
3 1 2 E51 B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E2 28 27 6 B134 B21 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134 ECM
19 16 29
EN-05687

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (LH) using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly LH. 3) Start the engine. 4) Read the data of tumble generator valve position sensor signal (LH) using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between tumble generator valve assembly LH connector and engine ground. Connector & terminal (E51) No. 2 Engine ground: Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair the short circuit to power in harness between ECM and tumble generator valve assembly LH connector.
CHECK POOR CONTACT. Check for poor contact of tumble generator valve assembly LH connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and tumble generator valve assembly LH connector Poor contact in ECM connector Poor contact of coupling connector Is there poor contact in the tum- Repair the poor Replace the tumble generator valve assembly contact of tumble ble generator valve LH connector? generator valve assembly LH. assembly LH con- <Ref. to nector. FU(H4DOTC)-41, Tumble Generator Valve Assembly.>
Go to step 4.

DK:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-199, DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137
ECM B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
17
16
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
21
22
B21 E2
E38 1 2
E38 1 2
EN-05688

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. FLOW CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve. Connector & terminal (B137) No. 17 (E38) No. 1: (B137) No. 16 (E38) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve connector. Replace the oil flow control solenoid valve. <Ref. to ME(H4DOTC)-58, Camshaft.>
CHECK HARNESS BETWEEN ECM AND OIL FLOW CONTROL SOLENOID VALVE. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 17 Chassis ground: (B137) No. 16 Chassis ground: CHECK OIL FLOW CONTROL SOLENOID VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 No. 2:
Go to step 3.
Is the resistance between 6 Repair the poor 12 :? contact of ECM and oil flow control solenoid valve connector.

DL:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-200, DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137
ECM B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
17
16
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
21
22
B21 E2
E38 1 2
E38 1 2
EN-05688

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 17 (+) Chassis ground (): (B137) No. 16 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 3. FLOW CONTROL SOLENOID VALVE. Measure the resistance of harness between ECM and oil flow control solenoid valve connector. Connector & terminal (B137) No. 17 (E38) No. 1: (B137) No. 16 (E38) No. 2: No Repair the short circuit to power in harness between ECM and oil flow control solenoid valve connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector CHECK OIL FLOW CONTROL SOLENOID Replace the oil Is the resistance between 6 Repair the poor VALVE. flow control sole12 :? contact of ECM Measure the resistance between oil flow control and oil flow control noid valve. <Ref. to solenoid valve terminals. solenoid valve con- ME(H4DOTC)-58, Terminals Camshaft.> nector. No. 1 No. 2:

DM:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-201, DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
15
14
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
32
33
B21 E2
E37 1 2
E37 1 2
EN-05689

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. FLOW CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve. Connector & terminal (B137) No. 15 (E37) No. 1: (B137) No. 14 (E37) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve connector. Replace the oil flow control solenoid valve. <Ref. to ME(H4DOTC)-58, Camshaft.>
Go to step 3.

DN:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-201, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
15
14
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
32
33
B21 E2
E37 1 2
E37 1 2
EN-05689

Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector CHECK OIL FLOW CONTROL SOLENOID Replace the oil Is the resistance between 6 Repair the poor VALVE. flow control sole12 :? contact of ECM Measure the resistance between oil flow control and oil flow control noid valve. <Ref. to solenoid valve terminals. solenoid valve con- ME(H4DOTC)-58, Terminals Camshaft.> nector. No. 1 No. 2:
DO:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
NOTE: Refer to DTC P2097 for diagnostic procedure. <Ref. to EN(H4DOTC)(diag)-311, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DP:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-204, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4
B47
42
1 3 5
2 4 6
E
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B134 E2 43 26 15 B21
* *
B138 B8 B9 C2 C3 B1
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B135
B:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C: B136 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 D: B21 B137
34 35 36 37 40
E2
*
E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 B138
1 2 3 4 5 6 7 8
EN-05669

MAIN RELAY SBF-5 5 3 6 4 2 1 B47 REAR OXYGEN SENSOR T6 B19 2 T5 2 BATTERY B19 T6 1 2 3 4 B83 B138
B47
1 3 5
2 4 6
1 2 3 4 5 6 7 8
B21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
T5 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
3 3
4 B19
*1 *1 * *
B30 C4 B4 B1 2 2
B83 A: B134 B138 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B21 34 35 36 37 40 E2
*1 *2
E
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05670

Yes No Check DTC using Go to step 2. List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> CHECK FRONT OXYGEN (A/F) SENSOR Has water entered the connec- Completely Go to step 3. CONNECTOR AND COUPLING CONNECtor? remove any water TOR. inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the harness FRONT OXYGEN (A/F) SENSOR CONNECand connector. TOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM and the following item: front oxygen (A/F) sensor. Open circuit in 3) Measure the resistance of harness between harness between ECM and front oxygen (A/F) sensor connector. ECM and front oxyConnector & terminal gen (A/F) sensor (B135) No. 9 (E79) No. 1: connector (B135) No. 8 (E79) No. 3: Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Go to step 5. Repair the ground FRONT OXYGEN (A/F) SENSOR CONNEC- more? short circuit of harTOR. ness between Measure the resistance between ECM and ECM and front oxychassis ground. gen (A/F) sensor Connector & terminal connector. (B135) No. 9 Chassis ground: (B135) No. 8 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.5 V or more? Go to step 7. Go to step 6. 1) Connect the ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E79) No. 1 (+) Chassis ground (): CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.95 V or more? Go to step 7. Go to step 8. Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E79) No. 3 (+) Chassis ground (): Repair the poor CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 8 V or more? Repair the short Measure the voltage between front oxygen (A/F) circuit to power in contact of ECM connector. sensor connector and chassis ground. the harness Connector & terminal between ECM and (E79) No. 1 (+) Chassis ground (): front oxygen (A/F) (E79) No. 3 (+) Chassis ground (): sensor connector. After repair, replace the ECM. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).> CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 9. on exhaust system? system. Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Step CHECK AIR INTAKE SYSTEM. Check Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 284 314 kPa (2.9 3.2 kgf/cm2, WARNING: Place NO OPEN FLAMES signs near the 41 46 psi)? working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. <Ref. to ME(H4DOTC)-25, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze the fuel return hose 2 to 3 times, then measure fuel pressure again. CHECK FUEL PRESSURE. Is the measured value 230 After connecting the pressure regulator vacuum 260 kPa (2.35 2.65 kgf/cm2, 33 38 psi)? hose, measure fuel pressure. <Ref. to ME(H4DOTC)-25, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. If the measured value at this step is out of specification, check or replace pressure regulator and pressure regulator vacuum hose. Yes Repair the air intake system. Go to step 11. No Go to step 10.
10
Repair the following item. Fuel pressure is too high: Clogged fuel return line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel supply line
11
Go to step 12.
12
CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Go to step 13. SENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual.
Repair the following item. Fuel pressure is too high: Faulty pressure regulator Clogged fuel return line or bent hose Fuel pressure is too low: Faulty pressure regulator Improper fuel pump discharge Clogged fuel supply line Replace the engine coolant temperature sensor. <Ref. to FU(H4DOTC)-31, Engine Coolant Temperature Sensor.>

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) For AT models, set the select lever to P range or N range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the measured value 2.0 5.0 g/s (0.26 0.66 lb/s) ? Yes Go to step 14. No Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H4DOTC)-36, Mass Air Flow and Intake Air Temperature Sensor.>
13
14

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Depress the clutch pedal. (MT model) Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: Depress the clutch pedal. (MT model) Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. Check Yes Is the voltage 490 mV or more? Go to step 16. No Go to step 17.
15
16
Go to step 17.
17
18
Has water entered the connec- Completely Go to step 19. tor? remove any water inside. CHECK FRONT OXYGEN (A/F) SENSOR Replace the front Go to step 19. Is a voltage of 0.8 V or more AND REAR OXYGEN SENSOR DATA. oxygen (A/F) senmaintained for 5 minutes or 1) Warm up the engine until engine coolant sor. <Ref. to more? temperature is higher than 75C (167F), then FU(H4DOTC)-46, keep the engine idling for 5 minutes or more. Front Oxygen (A/F) 2) Read the data of rear oxygen sensor signal Sensor.> using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 20. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (T6) No. 3: (B135) No. 30 (T6) No. 4: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H4DOTC)-48, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact in ECM connector Poor contact of coupling connector
19
20
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (T6) No. 3 (+) Chassis ground ():

DQ:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-206, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31
EN-05673

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 8 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 8: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: Check Yes Is the resistance less than 1 :? Go to step 2. No Replace the electronic throttle control relay. <Ref. to FU(H4DOTC)-55, Electronic Throttle Control Relay.>
Go to step 3.
Go to step 5.
Repair the ground short circuit of harness between ECM and electronic throttle control relay.
Go to step 7.

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 M: or 1) Connect the ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Yes Go to step 8. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 11.
10
11
Go to step 12.

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> CHECK SENSOR OUTPUT. Is the voltage 1.64 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> Yes Go to step 13. No Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4DOTC)-14, Throttle Body.> Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4DOTC)-14, Throttle Body.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control Poor contact of coupling connector Go to step 16.
12
13
Go to step 14.
14
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 15. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B137) No. 5 (E57) No. 2: (B137) No. 4 (E57) No. 1: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) Engine ground (): (E57) No. 1 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 Engine ground: (E57) No. 1 Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between the electronic throttle control connector terminals. Connector & terminal (E57) No. 2 (E57) No. 1: Is the voltage 5 V or more? Repair the short circuit to power in the harness between ECM and electronic throttle control.
15
16
Go to step 17.
17
Go to step 18.

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers. Check Yes Is the resistance less than 5 :? Go to step 19. No Repair the open circuit in harness between ECM and engine ground.
18
19
Replace the electronic throttle control. <Ref. to FU(H4DOTC)-14, Throttle Body.> Replace the electronic throttle control. <Ref. to FU(H4DOTC)-14, Throttle Body.>
20

DR:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-208, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05673

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 8 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 8: Check Yes Is the resistance less than 1 :? Go to step 2. No Replace the electronic throttle control relay. <Ref. to FU(H4DOTC)-55, Electronic Throttle Control Relay.>
Go to step 3.
Go to step 5.

DS:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-210, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05673

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUPPLY. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 8 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 21 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Replace the electronic throttle control relay. <Ref. to FU(H4DOTC)-55, Electronic Throttle Control Relay.>
DT:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE


DU:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-214, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B315
1 2 3 4 5 6
B83 4 6 5 1 3 2 B122
B315
1 2 3 4 5 6 7 8
B21
* *
B21 B23 B29 B22 B31 A: B134 B30 B122
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
A: B: B135 C: B136 D: B137 D1 C6 D3 D2 D7 A5 ECM 1 8 9 18 19 28 29 2 10 20 30
B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31
B21 37 34 40 35 36 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05690

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 21 Chassis ground: (B135) No. 23 Chassis ground: (B135) No. 23 (B136) No. 6: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector.
Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).>

DV:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-216, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B315
1 2 3 4 5 6
B83 4 6 5 1 3 2 B122
B315
1 2 3 4 5 6 7 8
B21
* *
B21 B23 B29 B22 B31 A: B134 B30 B122
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31
B21 37 34 40 35 36 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05690

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 :? Go to step 2. CELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 23 (B315) No. 6: (B135) No. 29 (B315) No. 5: CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 :? Go to step 3. CELERATOR PEDAL POSITION SENSOR. 1) Connect the ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 Chassis ground: No Repair the open circuit in harness between ECM and accelerator pedal position sensor connector.

DW:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-218, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B315
1 2 3 4 5 6
B83 4 6 5 1 3 2 B122
B315
1 2 3 4 5 6 7 8
B21
* *
B21 B23 B29 B22 B31 A: B134 B30 B122
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31
B21 37 34 40 35 36 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05690

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 22 Chassis ground: (B135) No. 31 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector.
Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).>

DX:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-220, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B315
1 2 3 4 5 6
B83 4 6 5 1 3 2 B122
B315
1 2 3 4 5 6 7 8
B21
* *
B21 B23 B29 B22 B31 A: B134 B30 B122
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31
B21 37 34 40 35 36 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05690

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 :? Go to step 2. CELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 31 (B315) No. 3: (B135) No. 30 (B315) No. 2: CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 :? Go to step 3. CELERATOR PEDAL POSITION SENSOR. 1) Connect the ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 2 Chassis ground: No Repair the open circuit in harness between ECM and accelerator pedal position sensor connector.

DY:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-222, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY B47 C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 D1 D7 A5
C6
B122
37 35 34 40 36
28 39 38 6
24
E2
25
B21
* * *
E
5 1 2 3
B362
B122 1 2 3 4 5 6 7 8
B21
E57
B47 1 3 5 2 4 6
1 2
3 4
5 7 8 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
1 2 3 4 5 6
A: B134
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
C:
B136
D:
B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05673

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Go to step 3.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 6.

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 (B134) No. 18: (B134) No. 19 (B134) No. 28: Yes Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H4DOTC)-14, Throttle Body.> No Repair the short circuit to power in the harness between ECM and electronic throttle control connector.

DZ:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-224, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B315
1 2 3 4 5 6
B83 4 6 5 1 3 2 B122
B315
1 2 3 4 5 6 7 8
B21
* *
B21 B23 B29 B22 B31 A: B134 B30 B122
* *
B83
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31
B21 37 34 40 35 36 E2
C: B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05690

Step CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal Main accelerator pedal position sensor signal (B135) No. 23 (+) Chassis ground (): Sub accelerator pedal position sensor signal (B135) No. 31 (+) Chassis ground (): CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) Chassis ground (): (B315) No. 3 (+) Chassis ground (): Check Yes Is the difference in measured Go to step 3. values for the main accelerator pedal position sensor signal and the sub accelerator pedal position sensor signal 0 V? No Go to step 2.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and accelerator pedal position sensor connector. Short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and accelerator pedal position sensor connector. Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector

EA:DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-226, DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE 2. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve 2. 3) Measure the resistance between the purge control solenoid valve 2 connector and engine ground. Connector & terminal (E52) No. 2 Engine ground: CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE 2. Measure the resistance of harness between ECM and purge control solenoid valve 2. Connector & terminal (B136) No. 7 (E52) No. 2: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Repair the ground short circuit of harness between ECM and purge control solenoid valve 2 connector.
CHECK PURGE CONTROL SOLENOID Is the resistance between 10 VALVE 2. 100 :? 1) Remove the purge control solenoid valve 2. 2) Measure the resistance between purge control solenoid valve 2 terminals. Terminals No. 1 No. 2: CHECK POWER SUPPLY TO PURGE CON- Is the voltage 10 V or more? TROL SOLENOID VALVE 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between purge control solenoid valve 2 and engine ground. Connector & terminal (E52) No. 1 (+) Engine ground ():
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and purge control solenoid valve 2 connector Poor contact of coupling connector Replace the purge control solenoid valve 2. <Ref. to EC(H4DOTC)-9, Purge Control Solenoid Valve.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the main relay and purge control solenoid valve 2 Poor contact of coupling connector Poor contact of main relay connector
Repair the poor contact in the purge control solenoid valve 2 connector.

EB:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-227, DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 7 48 11 44 E4 2 1 1 2 39 52 53 40 46 54 41 47 B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 R1 B21 E2
R15 1 5 6 R213
R46 R67
R144 2 1 1 2
R68
E52
DRAIN VALVE
E4 E52 R68
R144 1 2
R213 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2
B47
C:
B136 5 6 14 15 16 25 26 27 33 34 35
D:
B137
1 3 5
2 4 6
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-05679

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? PURGE CONTROL SOLENOID VALVE 2. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve 2. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 7 (+) Chassis ground (): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 :? VALVE 2. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve 2 terminals. Terminals No. 1 No. 2: Yes No Repair the short to Go to step 2. power in the harness between ECM and purge control solenoid valve 2 connector.
Replace the purge Repair the poor control solenoid contact of ECM valve 2. <Ref. to connector. EC(H4DOTC)-9, Purge Control Solenoid Valve.>

EC:DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-228, DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> Is the actual difference with atmo- Replace the secspheric pressure 200 mmHg ondary air combi(27 kPa, 8 inHg, 3.9 psig) or nation valve RH. more? <Ref. to EC(H4DOTC)-22, Secondary Air Combination Valve.> No Go to step 2.
CHECK CURRENT DATA. 1) Turn the ignition switch to ON (engine OFF). 2) Using the Subaru Select Monitor, read secondary air piping pressure, intake pipe absolute pressure and atmospheric pressure, and compare with the actual atmospheric pressure. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.>
Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

ED:DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-229, DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Turn the ignition switch to ON. 53.3 kPa (400 mmHg, 15.8 inHg)? 2) Read the data of secondary air piping pressure signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF SECONDARY Is the voltage 4.5 V or more? Go to step 3. AIR COMBINATION VALVE RH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the secondary air combination valve RH. 3) Turn the ignition switch to ON. 4) Measure the voltage between the secondary air combination valve RH connector and chassis ground. Connector & terminal (E41) No. 1 (+) Chassis ground (): No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and secondary air combination valve RH connector Poor contact in ECM connector Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the harness SECONDARY AIR COMBINATION VALVE and connector. RH CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM. the following item: 3) Measure the resistance of the harness Open circuit in between the ECM and secondary air combinaharness between tion valve RH connector. ECM and secondConnector & terminal ary air combination (B134) No. 27 (E41) No. 2: valve RH connector Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Go to step 5. Repair the ground SECONDARY AIR COMBINATION VALVE more? short circuit of harRH CONNECTOR. ness between Measure the resistance between ECM and ECM and secondchassis ground. ary air combination Connector & terminal valve RH connec(B134) No. 27 Chassis ground: tor. Replace the secCHECK POOR CONTACT. Is there poor contact in the Repair the poor Check for poor contact in the ECM and second- ECM or secondary air combi- contact in the ECM ondary air combination valve RH. ary air combination valve RH connector. nation valve RH connector? or secondary air combination valve <Ref. to EC(H4DOTC)-22, RH connector. Secondary Air Combination Valve.>

EE:DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-230, DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Read the data of secondary air piping pressure signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the secondary air combination valve RH. 3) Turn the ignition switch to ON. 4) Read the data of secondary air piping pressure signal using Subaru Select Monitor or general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of the harness between the secondary air combination valve RH connector and engine ground. Connector & terminal (E41) No. 3 Engine ground: Check Yes Is the measured value 133.3 kPa Go to step 2. (1000 mmHg, 39.4 inHg) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is the measured value 133.3 kPa Repair the short circuit to power in (1000 mmHg, 39.4 inHg) or more? the harness between ECM and secondary air combination valve RH connectors.
CHECK POOR CONTACT. Check for poor contact of the secondary air combination valve RH connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and secondary air combination valve RH connector Poor contact in ECM connector Poor contact of coupling connector Is there poor contact of the sec- Repair the poor Replace the secondary air combination valve contact of the secondary air combiRH connector? ondary air combination valve RH. nation valve RH <Ref. to connector. EC(H4DOTC)-22, Secondary Air Combination Valve.>

EF:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK1)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-231, DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK SECONDARY AIR COMBINATION VALVE FUSE. Check if the secondary air combination valve fuse (10 A) is blown out. CHECK HARNESS BETWEEN FUSE BOX AND SECONDARY AIR COMBINATION VALVE RH. 1) Remove the secondary air combination valve fuse (10 A) from the fuse box. 2) Disconnect the connector from the secondary air combination valve RH. 3) Measure the resistance between the secondary air combination valve fuse and secondary air combination valve RH connector, and chassis ground. Connector & terminal (F9) No. 5 Chassis ground: (E41) No. 6 Chassis ground: CHECK SECONDARY AIR COMBINATION VALVE RH OPERATION. 1) Connect the delivery (test) mode connector. 2) Turn the ignition switch to ON. 3) Perform operation check for the secondary air combination valve RH using the Subaru Select Monitor. NOTE: Refer to Compulsory Valve Operation Check Mode for more operation procedures. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK DUCT BETWEEN SECONDARY AIR PUMP AND SECONDARY AIR COMBINATION VALVE RH. Check the duct between the secondary air pump and secondary air combination valve RH. CHECK PIPE BETWEEN SECONDARY AIR COMBINATION VALVE RH AND CYLINDER HEAD. Check the pipe between the secondary air combination valve RH and cylinder head. Check Is the fuse blown out? Yes Go to step 2. No Go to step 3.
Replace the fuse with a new part, and connect the secondary air combination valve RH connector. Go to step 3.
Repair the ground short circuit of harness between the fuse box and the secondary air combination valve RH.
Does the secondary air combi- Go to step 4. nation valve RH repeatedly switch to ON and OFF?
Go to step 6.
Go to step 5.
Is there damage, clog or disconnection of the pipe?
Replace, clean or connect the pipe.
CHECK POWER SUPPLY TO SECONDARY Does the voltage repeatedly AIR COMBINATION VALVE RH. change between 10 V and 0 V? 1) Disconnect the connector from the secondary air combination valve RH. 2) In the condition of step 3, measure the voltage between the secondary air combination valve RH and the chassis ground. Connector & terminal (E41) No. 6 (+) Chassis ground ():
Replace the secondary air combination valve RH. <Ref. to EC(H4DOTC)-22, Secondary Air Combination Valve.>
Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 7.

Step CHECK HARNESS BETWEEN SECONDARY AIR COMBINATION VALVE RH AND CHASSIS GROUND. Measure the resistance between the secondary air combination valve RH connector and chassis ground. Connector & terminal (E41) No. 4 Chassis ground: CHECK HARNESS BETWEEN SECONDARY AIR COMBINATION VALVE RELAY 1 AND SECONDARY AIR COMBINATION VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the secondary air combination valve relay 1 from the relay box. 3) Measure the resistance of the harness between the secondary air combination valve relay 1 and secondary air combination valve RH connector. Connector & terminal (F9) No. 3 (E41) No. 6: CHECK SECONDARY AIR COMBINATION VALVE RELAY 1. 1) Connect the battery to terminals No. 1 and No. 2 of the secondary air combination valve relay 1. 2) Measure the resistance between the secondary air combination valve relay 1 terminals. Terminals No. 3 No. 4: CHECK SECONDARY AIR COMBINATION VALVE RELAY 1. Measure the resistance between the secondary air combination valve relay 1 terminals with the battery disconnected. Terminals No. 3 No. 4: CHECK SECONDARY AIR COMBINATION VALVE RELAY 1 POWER SOURCE. 1) Turn the ignition switch to ON. 2) Measure the voltage between the secondary air combination valve relay 1 connector and chassis ground. Connector & terminal (F9) No. 4 (+) Chassis ground (): (F9) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 1 CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector of ECM. 3) Measure the resistance of harness between ECM and secondary air combination valve relay 1 connector. Connector & terminal (B136) No. 30 (F9) No. 2: Check Yes Is the resistance less than 5 :? Go to step 8. No Repair the open circuit of harness between secondary air combination valve RH and chassis ground.
Repair the open circuit of the harness between the secondary air combination valve relay 1 and secondary air combination valve RH connector.
Replace the secondary air combination valve relay 1. <Ref. to EN(H4DOTC)(diag) -8, Electrical Component Location.>
10
Go to step 11.
11
Go to step 12.
Replace the secondary air combination valve relay 1. <Ref. to EN(H4DOTC)(diag) -8, Electrical Component Location.> Repair the open or ground short circuit of power supply circuit.
12
Repair the open circuit of harness between ECM and secondary air combination valve relay 1 connector.

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or SECONDARY AIR COMBINATION VALVE more? RELAY 1 CONNECTOR. Measure the resistance between the secondary air combination valve relay 1 connector and chassis ground. Connector & terminal (F9) No. 2 Chassis ground: Yes Repair the poor contact of ECM connector. No Repair the ground short circuit of harness between ECM and secondary air combination valve relay 1 connector.
13
EG:DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK1)
NOTE: For the diagnostic procedure, refer to DTC P2440. <Ref. to EN(H4DOTC)(diag)-353, DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EH:DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-231, DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK SECONDARY AIR COMBINATION VALVE FUSE. Check if the secondary air combination valve fuse (10 A) is blown out. CHECK HARNESS BETWEEN FUSE BOX AND SECONDARY AIR COMBINATION VALVE LH. 1) Remove the secondary air combination valve fuse (10 A) from the fuse box. 2) Disconnect the connector from the secondary air combination valve LH. 3) Measure the resistance between the secondary air combination valve fuse and secondary air combination valve LH connector, and chassis ground. Connector & terminal (F9) No. 5 Chassis ground: (E40) No. 2 Chassis ground: CHECK SECONDARY AIR COMBINATION VALVE LH OPERATION. 1) Connect the delivery (test) mode connector. 2) Turn the ignition switch to ON. 3) Perform operation check for the secondary air combination valve LH using the Subaru Select Monitor. NOTE: Refer to Compulsory Valve Operation Check Mode for more operation procedures. <Ref. to EN(H4DOTC)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK DUCT BETWEEN SECONDARY AIR PUMP AND SECONDARY AIR COMBINATION VALVE LH. Check the duct between the secondary air pump and secondary air combination valve LH. CHECK PIPE BETWEEN SECONDARY AIR COMBINATION VALVE LH AND CYLINDER HEAD. Check the pipe between the secondary air combination valve LH and cylinder head. Check Is the fuse blown out? Yes Go to step 2. No Go to step 3.
Replace the fuse with a new part, and connect the secondary air combination valve LH connector. Go to step 3.
Repair the ground short circuit of harness between the fuse box and the secondary air combination valve LH.
Does the secondary air combi- Go to step 4. nation valve LH repeatedly switch to ON and OFF?
Go to step 6.
Go to step 5.
Is there damage, clog or disconnection of the pipe?
Replace, clean or connect the pipe.
CHECK POWER SUPPLY TO SECONDARY Does the voltage repeatedly AIR COMBINATION VALVE LH. change between 10 V and 0 V? 1) Disconnect the connector from the secondary air combination valve LH. 2) In the condition of step 3, measure the voltage between the secondary air combination valve LH and the chassis ground. Connector & terminal (E40) No. 2 (+) Chassis ground ():
Replace the secondary air combination valve LH. <Ref. to EC(H4DOTC)-22, Secondary Air Combination Valve.>
Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 7.

Step CHECK HARNESS BETWEEN SECONDARY AIR COMBINATION VALVE LH AND CHASSIS GROUND. Measure the resistance between the secondary air combination valve LH connector and chassis ground. Connector & terminal (E40) No. 1 Chassis ground: CHECK HARNESS BETWEEN SECONDARY AIR COMBINATION VALVE RELAY 2 AND SECONDARY AIR COMBINATION VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the secondary air combination valve relay 2 from the relay box. 3) Measure the resistance of the harness between the secondary air combination valve relay 2 and secondary air combination valve LH connector. Connector & terminal (F9) No. 8 (E40) No. 2: CHECK SECONDARY AIR COMBINATION VALVE RELAY 2. 1) Connect the battery to terminals No. 10 and No. 9 of the secondary air combination valve relay 2. 2) Measure the resistance between the secondary air combination valve relay 2 terminals. Terminals No. 7 No. 8: CHECK SECONDARY AIR COMBINATION VALVE RELAY 2. Measure the resistance between the secondary air combination valve relay 2 terminals with the battery disconnected. Terminals No. 7 No. 8: CHECK SECONDARY AIR COMBINATION VALVE RELAY 2 POWER SOURCE. 1) Turn the ignition switch to ON. 2) Measure the voltage between the secondary air combination valve relay 2 connector and chassis ground. Connector & terminal (F9) No. 7 (+) Chassis ground (): (F9) No. 10 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND SECONDARY AIR COMBINATION VALVE RELAY 2 CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector of ECM. 3) Measure the resistance of harness between ECM and secondary air combination valve relay 2 connector. Connector & terminal (B136) No. 19 (F9) No. 9: Check Yes Is the resistance less than 5 :? Go to step 8. No Repair the open circuit of harness between secondary air combination valve LH and chassis ground.
Repair the open circuit of the harness between the secondary air combination valve relay 2 and secondary air combination valve LH connector.
Replace the secondary air combination valve relay 2. <Ref. to EN(H4DOTC)(diag) -8, Electrical Component Location.>
10
Go to step 11.
11
Go to step 12.
Replace the secondary air combination valve relay 2. <Ref. to EN(H4DOTC)(diag) -8, Electrical Component Location.> Repair the open or ground short circuit of power supply circuit.
12
Repair the open circuit of harness between ECM and secondary air combination valve relay 2 connector.

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or SECONDARY AIR COMBINATION VALVE more? RELAY 2 CONNECTOR. Measure the resistance between the secondary air combination valve relay 2 connector and chassis ground. Connector & terminal (F9) No. 9 Chassis ground: Yes Repair the poor contact of ECM connector. No Repair the ground short circuit of harness between ECM and secondary air combination valve relay 2 connector.
13
EI: DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK2)
NOTE: For the diagnostic procedure, refer to DTC P2442. <Ref. to EN(H4DOTC)(diag)-358, DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EJ:DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-232, DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H4DOTC)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H4DOTC)(diag)-43, PROCEDURE, Inspection Mode.>.

WIRING DIAGRAM:
E
A: B134 C: B136
C30 C19 C8 A19 A27 A29
ECM
6 1 28 47 46
E
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21
1 3 5
2 4 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
B144 1 5 2 6 3 8 4 9 1 3 4 2
F9 11 9 7 8 10 12 14 15 16 13
B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 10 11 12 13 14
F37 5 6 7 8 9 15 16 17 18 19 20
5 6
EN-05678

Step CHECK SECONDARY AIR PIPING PRESSURE. 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, read secondary air piping pressure data, and compare with the actual atmospheric pressure. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H4DOTC)(diag)-34, Subaru Select Monitor.> Check Yes Is the actual difference with Go to step 2. barometric pressure 50 mmHg (6.7 kPa, 2.0 inHg, 0.97 psig) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Replace the secondary air combination valve LH. <Ref. to EC(H4DOTC)-22, Secondary Air Combination Valve.> Repair the ground short circuit of harness between ECM and secondary air pump relay connector.
CHECK SECONDARY AIR PUMP. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Check whether the secondary air pump is operating.
Is the secondary air pump oper- Go to step 3. ating?
CHECK HARNESS BETWEEN ECM AND SECONDARY AIR PUMP RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the secondary air pump relay from the relay box. 3) Measure the resistance between the secondary air pump relay connector and engine ground terminals. Connector & terminal (F9) No. 13 Engine ground: CHECK SECONDARY AIR PUMP RELAY. Measure the resistance between the secondary air pump relay terminals. Terminals No. 14 No. 11:
Go to step 4.
Repair the short circuit of harness to power supply between secondary air pump relay and secondary air pump connector.
Replace the secondary air pump relay. <Ref. to EN(H4DOTC)(diag) -8, Electrical Component Location.>
Diagnostic Procedure without Diagnostic Trouble Code (DTC)

21.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK SI-DRIVE (SUBARU INTELLIGENT DRIVE) SYSTEM
DIAGNOSIS: SI-DRIVE mode will not change. CAUTION: Note that the SI-DRIVE system performs the following control when changing modes. 1. When the engine is cold, the low coolant temperature display will light in the multi-information display meter. In this case, it will not be possible to change to the S# (sports sharp) mode. 2. If the engine is stopped in the S# (sports sharp) mode, it will be in the S (sports) mode when the engine is restarted. 3. If the engine is stopped in the S (sports) or I (intelligent) mode, then restarted, it will enter the mode it was on before stopping the engine. 4. If the malfunction indicator light becomes lit while the engine is running, it will enter the S (sports) mode. In this case, it will not be possible to change to the S# (sports sharp) or I (intelligent) mode. 5. If there is a possible engine coolant temperature overheat condition, it will not be possible to switch to the S# (sports sharp) mode. When driving in the S# (sports sharp) mode, it will enter the S (sports) mode.

1. EVEN WHEN THE SI-DRIVE MODE IS CHANGED, THE MULTI INFORMATION DISPLAY DOES NOT CHANGE, AND THE MODE DOES NOT SWITCH
WIRING DIAGRAM:
COMBINATION METER A: B12 B9 i10 B8 B: i11 A11 i1 24 9 B36 B68 ST1 12 ROLL CONNECTOR 2 C7 3 ST4 3 4 ST5 4 B68 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B: i11 A12
i54 2 R99 1 16
R43 15 C1 5 5 I
S#
E
SI-DRIVE S# SWITCH
SI-DRIVE SELECTOR
C7 1 2 3 4 5
ST4 1 2 3 4 5 6
ST5 1 2 3 4 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 i1
i54 1 2 3 4 5 6 7 8 9 10 11 12
R43 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
A:
i10 6 7 8 9 10 17 18 19 20 21 22 3 4 1 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 11 12 13 14 15 16
EN-06953
Step CHECK SI-DRIVE SELECTOR. 1) Disconnect the connector from the multiinformation display meter. 2) Measure the resistance between connectors when the SI-DRIVE selector is operated. Connector & terminal (i11) No. 9 (i11) No. 12: CHECK SI-DRIVE S# SWITCH. 1) Hold down the SI- DRIVE S# switch on the steering wheel. 2) Measure the resistance of harness between the multi-information display meter connector and chassis ground. Connector & terminal (i11) No. 8 Chassis ground:
Check Yes Does the resistance change as Go to step 2. shown below? S#: 2.14 3.2 k: I: 0.8 1.2 k: S: Less than 10 :
No Go to step 5.
Go to step 6.

Step CHECK POOR CONTACT. Check the following items. Cracked or improperly connected connector Broken connector pin Disconnection connector terminal RECHECK FAULT. 1) Connect all connectors. 2) Change the SI-DRIVE mode. Check Is there any abnormal condition? Yes No Correct the cause Go to step 4. of trouble.
Is there any abnormal condition?
Replace the multiinformation display meter. <Ref. to IDI-22, Combination Meter.>
CHECK SI-DRIVE SELECTOR HARNESS AND CONNECTOR. Check the following items. Short or open circuit in the harness Improperly connected or loose terminal in the SI-DRIVE selector connector Improperly connected or loose terminal in coupling connector CHECK SI-DRIVE S# SWITCH HARNESS AND CONNECTOR. Check the following items. Short or open circuit in the harness Improperly connected or loose terminal in steering roll connector Improperly connected or loose terminal in coupling connector RECHECK FAULT. 1) Connect all connectors. 2) Change the SI-DRIVE mode.
The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Correct the cause Go to step 7. of trouble.
Correct the cause Go to step 7. of trouble.
Replace the SIDRIVE selector or SI-DRIVE S# switch. <Ref. to FU(H4DOTC)-50, SI-DRIVE (SUBARU Intelligent Drive) Selector.> <Ref. to FU(H4DOTC)-51, SI-DRIVE (SUBARU Intelligent Drive) S# Switch.>
The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.

2. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR APPEARS IN THE MULTI INFORMATION DISPLAY APPROXIMATELY 5 SECONDS LATER
Step 1 CHECK DTC. Check Is DTC displayed? Yes No Check the correGo to step 2. sponding DTC using the List of Diagnostic Trouble Code (DTC) for each unit. For the diagnostic Go to step 3. procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
CHECK DISPLAY OF MULTI-INFORMATION DISPLAY METER. Check whether there are other errors displayed other than the Mode Change Error. Examples: Err is displayed in the external temperature or fuel consumption displays. FUEL gauge, TEMP gauge or ECO gauge does not move. CHECK MULTI-INFORMATION DISPLAY METER AND ECM.
Is there other errors displayed other than the Mode Change Error?
Is the multi-information display Replace the multimeter and ECM part numbers information discorrect? play meter. <Ref. to IDI-22, Combination Meter.>
Replace the multiinformation display meter or ECM to that of the correct part number. <Ref. to IDI-22, Combination Meter.> or <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).>
3. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR IS NOT DISPLAYED IN MULTI INFORMATION DISPLAY, AND S#, I, S FLASHES
NOTE: In this case, there may be a problem outside the SI-DRIVE system.
1 Step Check CHECK MALFUNCTION INDICATOR LIGHT. Does the malfunction indicator 1) Start the engine. light illuminate? 2) Check whether the malfunction indicator light is lit or not. Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4DOTC)(diag) -81, List of Diagnostic Trouble Code (DTC).> Investigate and Go to step 3. repair the cause of overheating.
CHECK ENGINE COOLANT TEMPERATURE GAUGE. 1) Turn the ignition switch to ON. 2) Check the engine coolant temperature gauge. CHECK DISPLAY OF MULTI-INFORMATION DISPLAY. 1) Turn the ignition switch to ON. 2) Change the SI-DRIVE mode. 3) Check the display of the multi-information display.
Is it overheating?
Do the displays S#, I, S of Replace the multithe multi-information display information disflash? play meter. <Ref. to IDI-22, Combination Meter.>
Perform test operation, and check the malfunction indicator and the coolant temperature gauge. If they are operating normally, end the diagnosis.


A: INSPECTION
1. ENGINE
NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H4DOTC)-100, Engine Trouble in General.>
Symptoms Problem parts 1) Electronic throttle control 2) Manifold absolute pressure sensor 3) Mass air flow and intake air temperature sensor 4) Ignition parts (*1) 1. Engine stalls during idling. 5) Engine coolant temperature sensor (*2) 6) Crankshaft position sensor (*3) 7) Camshaft position sensor (*3) 8) Fuel injection parts (*4) 1) Electronic throttle control 2) Manifold absolute pressure sensor 3) Mass air flow and intake air temperature sensor 4) Engine coolant temperature sensor (*2) 5) Ignition parts (*1) 2. Rough idling 6) Air intake system (*5) 7) Fuel injection parts (*4) 8) Crankshaft position sensor (*3) 9) Camshaft position sensor (*3) 10) Oxygen sensor 11) Fuel pump and fuel pump relay 1) Electronic throttle control 2) Engine coolant temperature sensor 3. Engine does not return to idle. 3) Manifold absolute pressure sensor 4) Mass air flow sensor 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Electronic throttle control 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay 4. Poor acceleration 6) Engine coolant temperature sensor (*2) 7) Crankshaft position sensor (*3) 8) Camshaft position sensor (*3) 9) A/C switch and A/C cut relay 10) Engine torque control signal circuit 11) Ignition parts (*1) 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5. Engine stalls, engine sags or hesitates at acceleration. 5) Camshaft position sensor (*3) 6) Purge control solenoid valve 7) Fuel injection parts (*4) 8) Fuel pump and fuel pump relay 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 6. Surging 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Throttle position sensor 8) Fuel pump and fuel pump relay

Symptoms Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor 4) Knock sensor 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay
7. Spark knock
*1: Check ignition coil and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check fuel injector, fuel pressure regulator and fuel filter. *5: Inspect air leak in air intake system.


GENERAL DESCRIPTION

A: LIST
DTC P0011 Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank1) Crankshaft Position - Camshaft Position Correlation (Bank2) Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) MAP/MAF - Throttle Position Correlation Mass or Volume Air Flow Circuit Range/Performance Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Range/Performance Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Index <Ref. to GD(H4DOTC)-10, DTC P0011 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-13, DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-13, DTC P0021 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-14, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-16, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-18, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-20, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-22, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-24, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-26, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-28, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-29, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-30, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-31, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-32, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-34, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-35, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-36, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-37, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0016
P0018
P0021
P0030 P0031
P0032
P0037
P0038
P0068 P0101
P0102 P0103 P0107
P0108
P0111
P0112 P0113 P0117 P0118
GD(H4DOTC)-2

GENERAL DESCRIPTION
DTC P0122 Item Throttle/Pedal Position Sensor/ Switch A Circuit Low Throttle/Pedal Position Sensor/ Switch A Circuit High Insufficient Coolant Temperature for Closed Loop Fuel Control Insufficient Engine Coolant Temperature For Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank1 Sensor2) System Too Lean (Bank 1) System Too Rich (Bank 1) Fuel Temperature Sensor A Circuit Range/Performance Fuel Temperature Sensor A Circuit Low Input Fuel Temperature Sensor A Circuit High Input Throttle/Pedal Position Sensor/ Switch B Circuit Low Throttle/Pedal Position Sensor/ Switch B Circuit High Index <Ref. to GD(H4DOTC)-38, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-39, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-40, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-42, DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-44, DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-46, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-48, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-50, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-53, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-55, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-57, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-58, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-63, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-65, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-66, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-67, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-70, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-71, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-72, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-73, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0123
P0125
P0126
P0128
P0131
P0132
P0133
P0134
P0137
P0138
P0139
P0140
P0171 P0172 P0181
P0182 P0183 P0222
P0223
GD(H4DOTC)-3

GENERAL DESCRIPTION
DTC P0230 P0244 Index <Ref. to GD(H4DOTC)-74, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Turbo/Super Charger Wastegate <Ref. to GD(H4DOTC)-76, DTC P0244 TURBO/SUPER CHARGER WASTESolenoid A Range/Performance GATE SOLENOID A RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Turbo/Super Charger Wastegate <Ref. to GD(H4DOTC)-78, DTC P0245 TURBO/SUPER CHARGER WASTESolenoid A Low GATE SOLENOID A LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Turbo/Super Charger Wastegate <Ref. to GD(H4DOTC)-79, DTC P0246 TURBO/SUPER CHARGER WASTESolenoid A High GATE SOLENOID A HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Cylinder 1 Misfire Detected <Ref. to GD(H4DOTC)-80, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Cylinder 2 Misfire Detected <Ref. to GD(H4DOTC)-85, DTC P0302 CYLINDER 2 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Cylinder 3 Misfire Detected <Ref. to GD(H4DOTC)-85, DTC P0303 CYLINDER 3 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Cylinder 4 Misfire Detected <Ref. to GD(H4DOTC)-85, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Knock Sensor 1 Circuit Low <Ref. to GD(H4DOTC)-86, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (Bank 1 or Single Sensor) (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> Knock Sensor 1 Circuit High <Ref. to GD(H4DOTC)-87, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (Bank 1 or Single Sensor) (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> Crankshaft Position Sensor A Circuit <Ref. to GD(H4DOTC)-88, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Crankshaft Position Sensor A Circuit <Ref. to GD(H4DOTC)-90, DTC P0336 CRANKSHAFT POSITION SENSOR Range/Performance A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Camshaft Position Sensor A Circuit <Ref. to GD(H4DOTC)-92, DTC P0340 CAMSHAFT POSITION SENSOR A (Bank 1 or Single Sensor) CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> Camshaft Position Sensor A Circuit <Ref. to GD(H4DOTC)-93, DTC P0345 CAMSHAFT POSITION SENSOR A (Bank 2) CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System <Ref. to GD(H4DOTC)-94, DTC P0410 SECONDARY AIR INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System Incor- <Ref. to GD(H4DOTC)-101, DTC P0411 SECONDARY AIR INJECTION SYSrect Flow Detected TEM INCORRECT FLOW DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System <Ref. to GD(H4DOTC)-102, DTC P0413 SECONDARY AIR INJECTION SYSSwitching Valve A Circuit Open TEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System <Ref. to GD(H4DOTC)-103, DTC P0414 SECONDARY AIR INJECTION SYSSwitching Valve A Circuit Shorted TEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System <Ref. to GD(H4DOTC)-103, DTC P0416 SECONDARY AIR INJECTION SYSSwitching Valve B Circuit Open TEM SWITCHING VALVE B CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System <Ref. to GD(H4DOTC)-103, DTC P0417 SECONDARY AIR INJECTION SYSSwitching Valve B Circuit Shorted TEM SWITCHING VALVE B CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System Con- <Ref. to GD(H4DOTC)-104, DTC P0418 SECONDARY AIR INJECTION SYStrol A Circuit Open TEM CONTROL A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> Item Fuel Pump Primary Circuit
P0245
P0246
P0301 P0302 P0303 P0304 P0327
P0328
P0335 P0336
P0340
P0345 P0410 P0411
P0413
P0414
P0416
P0417
P0418
GD(H4DOTC)-4

GENERAL DESCRIPTION
DTC P0420 Item Catalyst System Efficiency Below Threshold (Bank 1) Evaporative Emission System Incorrect Purge Flow Evaporative Emission Control System Leak Detected (Small Leak) Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission Control System Leak Detected (Very Small Leak) Evaporative Emission Control System Leak Detected (Fuel Cap Loose/ Off) Evaporative Emission System Purge Control Valve Circuit Low Evaporative Emission System Purge Control Valve Circuit High Fuel Level Sensor A Circuit Range/ Performance Fuel Level Sensor A Circuit Low Fuel Level Sensor A Circuit High Fuel Level Sensor Circuit Intermittent Vehicle Speed Sensor A Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Starter Request Circuit Index <Ref. to GD(H4DOTC)-105, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-107, DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-108, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-124, DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-126, DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-128, DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-130, DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-132, DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-133, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-133, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-134, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-136, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-138, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-140, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-142, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-144, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-147, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-148, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-149, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-150, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0441
P0442
P0447
P0448
P0451
P0452
P0453
P0456
P0457
P0458
P0459
P0461
P0462 P0463 P0464 P0500 P0506
P0507
P0512
GD(H4DOTC)-5

GENERAL DESCRIPTION
DTC P0513 P0600 P0604 Item Incorrect Immobilizer Key Serial Communication Link Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/ Performance (Bank 1) Transmission Control System (MIL Request) Park/Neutral Switch Input Circuit Low (AT Model) Neutral Switch Input Circuit Low (MT Model) Park/Neutral Switch Input Circuit High (AT Model) Neutral Switch Input Circuit High (MT Model) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Fuel Tank Pressure Control Solenoid Valve Circuit Low Secondary Air Injection System Switching Valve Stuck Open Secondary Air Injection System Control A Circuit Shorted Fuel Tank Pressure Control Sol. Valve Circuit High Vent Control Solenoid Valve Function Problem Positive Crankcase Ventilation (Blow-By) Function Problem Back-Up Voltage Circuit Malfunction Index <Ref. to GD(H4DOTC)-151, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-152, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-154, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-155, DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-156, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-159, DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-161, DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-162, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-163, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-164, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-165, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-166, DTC P1152 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-168, DTC P1153 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-170, DTC P1160 RETURN SPRING FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-172, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-174, DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-176, DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-177, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-179, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-181, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-183, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0605
P0607
P0638
P0700 P0851
P0851 P0852
P0852 P1152
P1153
P1160 P1400
P1410
P1418
P1420
P1443 P1491
P1560
GD(H4DOTC)-6

GENERAL DESCRIPTION
DTC P1570 P1571 P1572 P1574 P1576 P1577 P1578 P1602 P2004 Item Antenna Reference Code Incompatibility IMM Circuit Failure Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Control Module Programming Error Intake Manifold Runner Control Stuck Open (Bank 1) Intake Manifold Runner Control Stuck Open (Bank 2) Intake Manifold Runner Control Stuck Closed (Bank 1) Intake Manifold Runner Control Stuck Closed (Bank 2) Intake Manifold Runner Control Circuit / Open (Bank 1) Intake Manifold Runner Control Circuit Low (Bank 1) Intake Manifold Runner Control Circuit / Open (Bank 2) Intake Manifold Runner Control Circuit Low (Bank 2) Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 2) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 2) Intake Camshaft Position Actuator Control Circuit Low (Bank 1) Index <Ref. to GD(H4DOTC)-184, DTC P1570 ANTENNA, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-184, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-184, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-184, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-184, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-184, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-184, DTC P1578 METER FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-185, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-187, DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-188, DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-189, DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-190, DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-191, DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-192, DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-193, DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-194, DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-195, DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-196, DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-197, DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-198, DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-199, DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2005
P2006
P2007
P2008
P2009
P2011
P2012
P2016
P2017
P2021
P2022
P2088
GD(H4DOTC)-7

GENERAL DESCRIPTION
DTC P2089 Item Intake Camshaft Position Actuator Control Circuit High (Bank 1) Intake Camshaft Position Actuator Control Circuit Low (Bank 2) Intake Camshaft Position Actuator Control Circuit High (Bank 2) Index <Ref. to GD(H4DOTC)-200, DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-201, DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2092
P2093
P2096
P2097
P2101
P2102 P2103 P2109
P2122
P2123
P2127
P2128
P2135
P2138
P2419
P2420
P2431
P2432
<Ref. to GD(H4DOTC)-201, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> Post Catalyst Fuel Trim System Too <Ref. to GD(H4DOTC)-202, DTC P2096 POST CATALYST FUEL TRIM SYSLean (Bank 1) TEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> Post Catalyst Fuel Trim System Too <Ref. to GD(H4DOTC)-204, DTC P2097 POST CATALYST FUEL TRIM SYSRich (Bank 1) TEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Actuator Control Motor Circuit <Ref. to GD(H4DOTC)-206, DTC P2101 THROTTLE ACTUATOR CONTROL Range/Performance MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Actuator Control Motor Circuit <Ref. to GD(H4DOTC)-208, DTC P2102 THROTTLE ACTUATOR CONTROL Low MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Actuator Control Motor Circuit <Ref. to GD(H4DOTC)-210, DTC P2103 THROTTLE ACTUATOR CONTROL High MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor A <Ref. to GD(H4DOTC)-212, DTC P2109 THROTTLE/PEDAL POSITION SENMinimum Stop Performance SOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4DOTC)-214, DTC P2122 THROTTLE/PEDAL POSITION SENSwitch D Circuit Low Input SOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4DOTC)-216, DTC P2123 THROTTLE/PEDAL POSITION SENSwitch D Circuit High Input SOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4DOTC)-218, DTC P2127 THROTTLE/PEDAL POSITION SENSwitch E Circuit Low Input SOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4DOTC)-220, DTC P2128 THROTTLE/PEDAL POSITION SENSwitch E Circuit High Input SOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4DOTC)-222, DTC P2135 THROTTLE/PEDAL POSITION SENSwitch A/B Voltage Correlation SOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H4DOTC)-224, DTC P2138 THROTTLE/PEDAL POSITION SENSwitch D/E Voltage Correlation SOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission System Switch- <Ref. to GD(H4DOTC)-226, DTC P2419 EVAPORATIVE EMISSION SYSTEM ing Valve Control Circuit Low SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Evaporative Emission System Switch- <Ref. to GD(H4DOTC)-227, DTC P2420 EVAPORATIVE EMISSION SYSTEM ing Valve Control Circuit High SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System Air <Ref. to GD(H4DOTC)-228, DTC P2431 SECONDARY AIR INJECTION SYSFlow /Pressure Sensor Circuit Range/ TEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE, Performance Diagnostic Trouble Code (DTC) Detecting Criteria.> Secondary Air Injection System Air <Ref. to GD(H4DOTC)-229, DTC P2432 SECONDARY AIR INJECTION SYSFlow /Pressure Sensor Circuit Low TEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-8

GENERAL DESCRIPTION
DTC P2433 Item Secondary Air Injection System Air Flow /Pressure Sensor Circuit High Secondary Air Injection System Switching Valve Stuck Open (Bank1) Secondary Air Injection System Switching Valve Stuck Closed (Bank1) Secondary Air Injection System Switching Valve Stuck Open (Bank2) Secondary Air Injection System Switching Valve Stuck Closed (Bank2) Secondary Air Injection System Pump Stuck On Index <Ref. to GD(H4DOTC)-230, DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-231, DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-231, DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-231, DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-231, DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4DOTC)-232, DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2440
P2441
P2442
P2443
P2444
GD(H4DOTC)-9

GENERAL DESCRIPTION

Detect the AVCS system malfunction. Judge NG when the amount of AVCS actual timing advance does not approach to the amount of AVCS target timing advance.
(3) (1) (5) (2)
(4)
EN-01852
(1) (2)
AVCS timing controller Vane
(3) (4)
Engine control module (ECM) Oil flow control solenoid valve
(5)
Oil pressure
3. ENABLE CONDITION
Secondary Parameters Time of establishing all secondary parameter conditions Battery voltage Engine speed Engine coolant temperature AVCS control Target advance angle Target timing advance change amount (per 64 ms) Enable Conditions t 3000 ms t 10.9 V t 1300 rpm t 60 C (140 F) Operation t 0 CA < 1.07 CA

Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates.
GD(H4DOTC)-10

GENERAL DESCRIPTION
1) When the conditions during which the differences of AVCS target timing advance amount and AVCS actual timing advance amount is large continues for certain amount of time. 2) When the differences of target timing advance amount and actual timing advance amount is calculated during AVCS control, and the difference per predetermined time is the specified value or larger. Abnormality Judgement Judge as NG when the following conditions are established within the predetermined time. Judgement Value
Malfunction Criteria 6(Target position Actual position) Threshold Value > 8000 CA (AT model) (Bank 1) > 8000 CA (AT model) (Bank 2) > 5300 CA (MT model) (Bank 1) > 5300 CA (MT model) (Bank 2) < 8000 CA (AT model) (Bank 1) < 8000 CA (AT model) (Bank 2) < 5300 CA (MT model) (Bank 1) < 5300 CA (MT model) (Bank 2)
or 6(Target position Actual position)
Time Needed for Diagnosis: AT model: 30000 ms MT model: 20000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the following conditions are established within the predetermined time. Judgement Value
Malfunction Criteria 6(Target position Actual position) Threshold Value d 8000 CA (AT model) (Bank 1) d 8000 CA (AT model) (Bank 2) d 5300 CA (MT model) (Bank 1) d 5300 CA (MT model) (Bank 2) and t 8000 CA (AT model) (Bank 1) t 8000 CA (AT model) (Bank 2) t 5300 CA (MT model) (Bank 1) t 5300 CA (MT model) (Bank 2)
Time Needed for Diagnosis: AT model: 30000 ms MT model: 20000 ms
GD(H4DOTC)-11

GENERAL DESCRIPTION

Detect the AVCS system malfunction. Judge as NG when the timing advance is outside the normal range.
(3) (1) (5) (2)
(4)
EN-01852
(1) (2)
(3) (4)
(5)
Oil pressure
3. ENABLE CONDITION
Secondary Parameters Battery voltage Engine speed Engine coolant temperature AVCS control Target timing advance Enable Conditions t 10.9 V t 500 rpm t 60 C (140 F) Not in operation 0CA

Perform the diagnosis continuously after starting engine and while AVCS is not operating.
GD(H4DOTC)-12

GENERAL DESCRIPTION
Judge as NG when the camshaft sensor input position is not within the normal range. Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Crankshaft position when camshaft position sensor signal is input Threshold Value < BTDC 17 CA (Bank 1) < BTDC 17 CA (Bank 2) or > BTDC 55 CA (Bank 1) > BTDC 55 CA (Bank 2)
Malfunction Criteria Crankshaft position when camshaft position sensor signal is input Threshold Value t BTDC 17 CA (Bank 1) t BTDC 17 CA (Bank 2) and d BTDC 55 CA (Bank 1) d BTDC 55 CA (Bank 2)

NOTE: For the detection standard, refer to DTC P0016. <Ref. to GD(H4DOTC)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
NOTE: For the detection standard, refer to DTC P0011. <Ref. to GD(H4DOTC)-10, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-13

GENERAL DESCRIPTION
E: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

(1)
(2)
(4)
(3)
EN-02181
(1) (2)
(3)
Sensor housing
(4)
Protection tube
3. ENABLE CONDITION

GD(H4DOTC)-14

GENERAL DESCRIPTION
Malfunction Criteria Front oxygen (A/F) sensor impedance Threshold Value > 50 :
Malfunction Criteria Front oxygen (A/F) sensor impedance Threshold Value d 50 :
GD(H4DOTC)-15

GENERAL DESCRIPTION

(A) OFF (B)
ON 0V
(D)
(C)
EN-01792
(A) (B)
(C)
128 milliseconds
(D)
Low error
3. ENABLE CONDITION

GD(H4DOTC)-16

GENERAL DESCRIPTION
GD(H4DOTC)-17

GENERAL DESCRIPTION

(A) (D) (B) OFF
ON 0V
(C)
EN-01793
(A) (B)
(C)
128 milliseconds
(D)
High error
3. ENABLE CONDITION

GD(H4DOTC)-18

GENERAL DESCRIPTION
GD(H4DOTC)-19

GENERAL DESCRIPTION

(A) OFF (B)
ON 0V
(D)
(C)
EN-01792
(A) (B)
(C)
(D)
Low error
3. ENABLE CONDITION

GD(H4DOTC)-20

GENERAL DESCRIPTION
GD(H4DOTC)-21

GENERAL DESCRIPTION
I:
(A) (D) (B) OFF
ON 0V
(C)
EN-01793
(A) (B)
(C)
(D)
High error
3. ENABLE CONDITION

GD(H4DOTC)-22

GENERAL DESCRIPTION
GD(H4DOTC)-23

GENERAL DESCRIPTION
J: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4DOTC)-24

GENERAL DESCRIPTION
Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load Threshold Value < 2500 rpm t 10 <1V > 1.356 g/rev (0.05 oz/rev) 600 rpm 900 rpm < 2.75 t 2.36 V < 0.4 g/rev (0.01 oz/rev)
Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load Threshold Value < 2500 rpm t 10 t1V > 1.356 g/rev (0.05 oz/rev) 600 rpm 900 rpm < 2.75 < 2.36 V < 0.4 g/rev (0.01 oz/rev)
GD(H4DOTC)-25

GENERAL DESCRIPTION
K: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION

GD(H4DOTC)-26

GENERAL DESCRIPTION
Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High (1) Output voltage Engine speed Throttle opening angle Intake manifold pressure High (2) Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis Threshold Value < 1.5 V t 2500 rpm t 15 t 53.3 kPa (400 mmHg, 15.7 inHg) t 1.95 V 600 rpm 900 rpm < 4.1 t 52.7 kPa (395 mmHg, 15.6 inHg) t 1.70 V 600 rpm 900 rpm < 4.1 t 52.7 kPa (395 mmHg, 15.6 inHg) Rich side malfunction
Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis Threshold Value t 1.5 V t 2500 rpm t 15 t 53.3 kPa (400 mmHg, 15.7 inHg) < 1.95 V 600 rpm 900 rpm < 4.1 < 52.7 kPa (395 mmHg, 15.6 inHg) Rich side normal
GD(H4DOTC)-27

GENERAL DESCRIPTION
L: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION

GD(H4DOTC)-28

GENERAL DESCRIPTION
M: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION

GD(H4DOTC)-29

GENERAL DESCRIPTION
N: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT

(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4DOTC)-30

GENERAL DESCRIPTION
O: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT

(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4DOTC)-31

GENERAL DESCRIPTION
P: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/ PERFORMANCE

(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION
Secondary Parameters Engine coolant temperature at engine starting Engine coolant temperature Battery voltage Continuous time when the vehicle speed is less than 60 km/h (37.3 MPH Enable Conditions < 30 C (86 F) t 95 C (203 F) t 10.9 V t 600 s

GD(H4DOTC)-32

GENERAL DESCRIPTION
Malfunction Criteria Output voltage difference between Max. and Min. Threshold Value < 0.02 V(Equivalent to approximately 0.5C (0.9F) near 25C)
Malfunction Criteria Output voltage difference between Max. and Min. Threshold Value t 0.02 V
GD(H4DOTC)-33

GENERAL DESCRIPTION
Q: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION

GD(H4DOTC)-34

GENERAL DESCRIPTION
R: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION

GD(H4DOTC)-35

GENERAL DESCRIPTION
S: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4DOTC)-36

GENERAL DESCRIPTION
T: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4DOTC)-37

GENERAL DESCRIPTION
U: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-38

GENERAL DESCRIPTION
V: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-39

GENERAL DESCRIPTION
W: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION
Secondary Parameters Engine speed Battery voltage Enable Conditions t 500 rpm t 10.9 V

GD(H4DOTC)-40

GENERAL DESCRIPTION
0 (0) 20 (4) 10 (14) Temperature 0 (32) C (F) 10 (50) 20 (68) 0.000 ms 0.000 ms 0.000 ms 0.000 ms 0.000 ms 8 (5) 37.136 ms 27.391 ms 17.646 ms 7.9012 ms 7.9012 ms 16 (9.9) 74.272 ms 54.782 ms 35.292 ms 15.802 ms 15.802 ms Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 40 (24.9) 111.41 ms 82.173 ms 52.938 ms 23.704 ms 23.704 ms 126.66 ms 99.65 ms 72.64 ms 45.63 ms 45.63 ms 141.91 ms 117.13 ms 92.341 ms 67.556 ms 67.556 ms 48 (29.8) 163.59 ms 135.96 ms 108.34 ms 80.711 ms 80.711 ms 56 (34.8) 185.26 ms 154.8 ms 124.33 ms 93.867 ms 93.867 ms
GD(H4DOTC)-41

GENERAL DESCRIPTION
X: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION

(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H4DOTC)-42

GENERAL DESCRIPTION
t 5 C (41 F) < 2.5 C (36.5 F) < 35 C (95 F)
GD(H4DOTC)-43

GENERAL DESCRIPTION
Y: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
(8)
(2)
(2)
(7)
(6)
(5)
(9)
(4) (3)
(1)
EN-01692
(1) (2) (3)
(4) (5) (6)
(7) (8) (9)
3. ENABLE CONDITION

GD(H4DOTC)-44

GENERAL DESCRIPTION
Time Needed for Diagnosis: 64 ms 3 time(s) 152 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
GD(H4DOTC)-45

GENERAL DESCRIPTION
Z: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

Detect the open or short circuit of sensor. Judge as NG when the element applied voltage is out of range, or the element current is out of range.
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H4DOTC)-46

GENERAL DESCRIPTION
Malfunction Criteria Input voltage or Input current Threshold Value < 1.8 V < 0.01 A
Malfunction Criteria Input voltage Input current Threshold Value t 1.8 V t 0.01 A
GD(H4DOTC)-47

GENERAL DESCRIPTION
AA:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D) (4)
Rich Ceramic heater
(3)
ZrO2
3. ENABLE CONDITION

GD(H4DOTC)-48

GENERAL DESCRIPTION
Malfunction Criteria Input voltage or Input current Threshold Value > 3.8 V > 0.01 A
Malfunction Criteria Input voltage Input current Threshold Value d 3.8 V d 0.01 A
GD(H4DOTC)-49

GENERAL DESCRIPTION
AB:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

(2) (1)
(3)
EN-01694
(1)
Cover
(2)
Zirconia
(3)
Clogging
GD(H4DOTC)-50

GENERAL DESCRIPTION
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D) (4)
Rich Ceramic heater
(3)
ZrO2
3. ENABLE CONDITION

GD(H4DOTC)-51

GENERAL DESCRIPTION
Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n1) + |d2faf (n)| td2lmd (N) = td2lmd (n1) + |d2lmd (n)| add up to 32 ms 4 1640 time(s). d2faf (n) = (faf (n) faf (n1)) (faf (n1) faf (n2)) d2lmd (n) = (lmd (n) lmd (n1)) (lmd (n1) lmd (n2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds Threshold Value > 0.644 (AT model) > 0.444 (MT model)
Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n1) + |d2faf (n)| td2lmd (N) = td2lmd (n1) + |d2lmd (n)| add up to 32 ms 4 1640 time(s). d2faf (n) = (faf (n) faf (n1)) (faf (n1) faf (n2)) d2lmd (n) = (lmd (n) lmd (n1)) (lmd (n1) lmd (n2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds Threshold Value d 0.644 (AT model) d 0.444 (MT model)
GD(H4DOTC)-52

GENERAL DESCRIPTION
AC:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H4DOTC)-53

GENERAL DESCRIPTION
GD(H4DOTC)-54

GENERAL DESCRIPTION
AD:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
GD(H4DOTC)-55

GENERAL DESCRIPTION
3. ENABLE CONDITION

GD(H4DOTC)-56

GENERAL DESCRIPTION

Malfunction Criteria High Sensor output voltage Low Sensor output voltage Threshold Value P0138 > 1.2 V P0137 < 0.03 V DTC
Fuel Cut Time (millisecond) Time needed for diagnosis (millisecond) 0 150000 2000 150000 10000 150000
Malfunction Criteria High Sensor output voltage Low Sensor output voltage Threshold Value P0138 d 1.2 V P0137 t 0.03 V DTC
AE:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

NOTE: For the detection standard, refer to DTC P0137. <Ref. to GD(H4DOTC)-55, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-57

GENERAL DESCRIPTION
AF:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

Detect the slow response of the oxygen sensor. Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and Judge as OK if both are OK. [Rich o lean diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean. If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK. 2. Judge as NG when the oxygen sensor voltage is large (rich) when recovering from a deceleration fuel cut. [Lean o rich diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich. If the measured response time is larger than the threshold value, it is NG. 2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel cut. DIAGNOSTIC METHOD Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to lean. And Judge as NG when the measured response time is larger than the threshold value.
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION
GD(H4DOTC)-58

GENERAL DESCRIPTION

(A) (B)
EN-05566
(A) (B) (C) (D)
0.55 V 0.5 V 0.2 V 0.15 V
(E) (F) (G)
(H)
GD(H4DOTC)-59

GENERAL DESCRIPTION
Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V or Longest time over 0.55 V Threshold Value > 837 ms
t 2000 ms
Judgement Value
Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V Threshold Value d 837 ms
6. ENABLE CONDITION
Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time is 6000 ms or more. After fuel cut Current calculation time of the rear oxygen sensor heater Current continuation time of the rear oxygen sensor heater Estimated catalyst temperature Number of deceleration fuel cut Enable Conditions t 10.9 V Completed Experienced t 2000 ms t 0 ms t 0 ms t 0 C (32 F) t 1 time(s)
GD(H4DOTC)-60

GENERAL DESCRIPTION

(H)
(A) (B)
(C) (D) (E)
(J)
EN-05567
(A) (B) (C) (D) (E) (F)
(G) (H) (I)
(J)
GD(H4DOTC)-61

GENERAL DESCRIPTION
t 120000 ms
Judgement Value
Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V Threshold Value d 2000 ms
GD(H4DOTC)-62

GENERAL DESCRIPTION
AG:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)

(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)


GD(H4DOTC)-63

GENERAL DESCRIPTION
GD(H4DOTC)-64

GENERAL DESCRIPTION
AH:DTC P0171 SYSTEM TOO LEAN (BANK 1)

Detect fuel system malfunction by the amount of main feedback control. DIAGNOSTIC METHOD Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.
2. ENABLE CONDITION
Map1
Engine speed (rpm) Measured value (g(oz)/rev) Idling Non-turbo 800 0.228 (0.01) 1200 0.22 (0.01) 1600 0.22 (0.01) 2000 0.22 (0.01) 2400 0.228 (0.01) 2800 0.23 (0.01) 3200 0.234 (0.01) 3600 0.242 (0.01) 4000 0.25 (0.01) 4400 0.25 (0.01)

Malfunction Criteria fsobd = (sglmd tglmda) + faf + flaf In this case: sglmd = measured lambda tglmda = target lambda faf = main feedback compensation coefficient every 64 milliseconds flaf = main feedback learning compensation coefficient Threshold Value t Value of Map 2
Map2
Amount of air (g (oz)/s) fsobdL1 (%) 0 (0) 1.4 2.34375 (0.08) 1.4 4.6875 (0.17) 1.368623 7.03125 (0.25) 1.319185 9.375 (0.33) 1.26975 11.71875 (0.41) 1.265 14.0625 (0.5) 1.265
GD(H4DOTC)-65

GENERAL DESCRIPTION
AI: DTC P0172 SYSTEM TOO RICH (BANK 1)

2. ENABLE CONDITION
Map1

Malfunction Criteria Threshold Value fsobd = (sglmd tglmda) + faf + flaf < Value of Map 2 In this case: sglmd = measured lambda tglmda = target lambda faf = main feedback compensation coefficient every 64 milliseconds flaf = main feedback learning compensation coefficient
Map2
Amount of air (g (oz)/s) fsobdL1 (%) 0 (0) 0.6 2.34375 4.6875 7.03125 9.375 11.7187 14.0625 (0.08) (0.17) (0.25) (0.33) 5 (0.41) (0.5) 0.6 0.63137 0.68082 0.73025 0.73025 0.73025
GD(H4DOTC)-66

GENERAL DESCRIPTION
AJ:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/ PERFORMANCE

(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION
DRIFT DIAGNOSIS

GD(H4DOTC)-67

GENERAL DESCRIPTION
Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature Engine coolant temperature at engine start Fuel temperature Engine coolant temperature Battery voltage Threshold Value t 9.6 2 (2.54 US gal, 2.11 Imp gal) t 20 s > 10 C (50 F) t 10 C (50 F) t 10.9 V
Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature Engine coolant temperature at engine start Fuel temperature Engine coolant temperature Battery voltage Engine coolant temperature Threshold Value t 9.6 2 (2.54 US gal, 2.11 Imp gal) t 20 s > 10 C (50 F) < 10 C (50 F) t 10.9 V < 70 C (158 F)
6. ENABLE CONDITION
Stuck Diagnosis

GD(H4DOTC)-68

GENERAL DESCRIPTION
Malfunction Criteria Accumulated amount of intake air Fuel temperature difference between Max. and Min. Threshold Value t 551043 g (19435.29 oz) < 2 C (35.6 F)
Malfunction Criteria Fuel temperature difference between Max. and Min. Threshold Value t 2 C (35.6 F)
GD(H4DOTC)-69

GENERAL DESCRIPTION
AK:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION

GD(H4DOTC)-70

GENERAL DESCRIPTION
AL:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION

GD(H4DOTC)-71

GENERAL DESCRIPTION
AM:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-72

GENERAL DESCRIPTION
AN:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-73

GENERAL DESCRIPTION
AO:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

Detect the malfunction of fuel pump control unit. Judge as NG when the NG signal is sent through a diagnostic line coming from the fuel pump control unit. Fuel pump control unit detects the open or short circuit malfunction for each line, and then sends NG signals if one of them is found NG.
+B FPC (1) DI (2) FPFP+ (3) (4)
E
EN-01771
(1) (2)
Engine control module (ECM) Fuel pump control unit
(3)
Fuel pump
(4)
Battery
3. ENABLE CONDITION

GD(H4DOTC)-74

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level Threshold Value t8V t 180000 ms ON Low t 10 2 (2.64 US gal, 2.2 Imp gal)
Malfunction Criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level Threshold Value t8V t 180000 ms ON High t 10 2 (2.64 US gal, 2.2 Imp gal)
GD(H4DOTC)-75

GENERAL DESCRIPTION
AP:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A RANGE/PERFORMANCE

Detect the malfunction of wastegate control solenoid valve function. Judge as NG when becoming high wastegate pressure.
(1)
EN-01772
(1)
Coil
3. ENABLE CONDITIONS

GD(H4DOTC)-76

GENERAL DESCRIPTION
Malfunction Criteria Intake manifold pressure Threshold Value t Value from Map
Map
Pa (kPa (mmHg, inHg)) Abnormal threshold (kPa (mmHg, inHg)) 58.7 kPa 77.3 kPa 89.3 kPa 96 kPa 98.6 kPa 101.3 kPa (440 mmHg, (580 mmHg, (670 mmHg, (720 mmHg, (740 mmHg, (760 mmHg, 17.3 inHg) 22.8 inHg) 26.4 inHg) 28.3 inHg) 29.1 inHg) 29.9 inHg) 216.2 kPa 221.3 kPa 221.3 kPa 143.4 kPa 172.6 kPa 204.5 kPa (1076 mmHg, (1295 mmHg, (1534 mmHg, (1622 mmHg, (1660 mmHg, (1660 mmHg, 42.4 inHg) 51 inHg) 60.4 inHg) 63.9 inHg) 65.4 inHg) 65.4 inHg)
Malfunction Criteria Intake manifold pressure Threshold Value < Value from Map 22.4 kPa (168 mmHg, 6.6 inHg)
GD(H4DOTC)-77

GENERAL DESCRIPTION
AQ:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW

Detect open or short circuit of the wastegate control solenoid valve. Judge as NG when the terminal output voltage remains Low during outputting the duty signal.
(1)
EN-01772
(1)
Coil
3. ENABLE CONDITION

Malfunction Criteria Terminal output voltage Duty ratio of wastegate control Threshold Value Low < 75%
Time Needed for Diagnosis: 4 ms 160 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
GD(H4DOTC)-78

GENERAL DESCRIPTION
AR:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH

Detect open or short circuit of the wastegate control solenoid valve. Judge as NG when the terminal output voltage remains Low or High during outputting the duty signal.
(1)
EN-01772
(1)
Coil
3. ENABLE CONDITION

Malfunction Criteria Terminal output voltage Duty ratio of wastegate control Threshold Value High t 25%
Time Needed for Diagnosis: 4 ms 160 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
GD(H4DOTC)-79

GENERAL DESCRIPTION
AS:DTC P0301 CYLINDER 1 MISFIRE DETECTED

Detect the presence of misfire occurrence. (Revolution fluctuation method) Monitoring Misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made obligatory by the law. Misfire affecting these two has two patterns below. : Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.): FTP 1.5 times misfire Every time misfire (The same cylinder misfires every time.): FTP 1.5 times misfire, Catalyst damage misfire The following detecting methods are adopted for these detection. 1) Intermittent misfire: FTP 1.5 times misfire 180 Interval Difference Method (MT: 1,800 rpm or less, AT: None) 360 Interval Difference Method (whole range) 720 Interval Difference Method (3,000 rpm or more) 2) Misfire every time: FTP 1.5 times misfire, Catalyst damage misfire 360 Interval Difference Method
2. ENABLE CONDITION
Secondary Parameters All secondary parameters enable conditions Intake manifold pressure change at 180CA Throttle position change during 16 milliseconds Fuel shut-off function Fuel level Vehicle dynamic control or AT torque control Evaporative system leak check Engine speed Intake manifold pressure Battery voltage Fuel parameter determination Elapsed time after starting the engine Engine load change during 32 milliseconds Enable Conditions t 1024 ms < Value of Map 1 < 14 Not in operation t 9.6 2 (2.54 US gal, 2.11 Imp gal) Not in operation Not in operation 500 rpm 6500 rpm t Value from Map 2 t8V Not extremely low volatility t 0 ms < 1000 rpm
GD(H4DOTC)-80

GENERAL DESCRIPTION
Map1 AT model
rpm kPa (mmHg, inHg) 700 26.7 (200, 7.9) 1000 26.7 (200, 7.9) 1500 26.7 (200, 7.9) 2000 26.7 (200, 7.9) 2500 26.7 (200, 7.9) 3000 26.7 (200, 7.9) 3500 26.7 (200, 7.9) 4000 26.7 (200, 7.9) 4500 26.7 (200, 7.9) 5000 26.7 (200, 7.9) 5500 26.7 (200, 7.9) 6000 26.7 (200, 7.9) 6500 26.7 (200, 7.9) 6700 26.7 (200, 7.9)
MT model
rpm kPa (mmHg, inHg) 700 13.3 (100, 3.9) 1000 13.3 (100, 3.9) 1500 13.3 (100, 3.9) 2000 13.3 (100, 3.9) 2500 13.3 (100, 3.9) 3000 13.3 (100, 3.9) 3500 13.3 (100, 3.9) 4000 13.3 (100, 3.9) 4500 13.3 (100, 3.9) 5000 13.3 (100, 3.9) 5500 13.3 (100, 3.9) 6000 13.3 (100, 3.9) 6500 13.3 (100, 3.9) 6700 13.3 (100, 3.9)
Map2 AT model (Tumble generator valve open)

rpm kPa (mmHg, inHg) 700 29.3 (220, 8.7) 1000 26.7 (200, 7.9) 1500 26.7 (200, 7.9) 2000 26.7 (200, 7.9) 2500 27.3 (205, 8.1) 3000 28 (210, 8.3) 3500 29.5 (221.5, 8.7) 4000 31.3 (235, 9.3) 4500 32.7 (245.5, 9.7) 5000 34.1 (256, 10.1) 5500 38.2 (286.5, 11.3) 6000 44 (330, 13) 6500 49.5 (371.5, 14.6) 6700 53.3 (400, 15.7)
AT model (Tumble generator valve closed)

rpm kPa (mmHg, inHg) 700 29.3 (220, 8.7) 1000 26.7 (200, 7.9) 1500 26.7 (200, 7.9) 2000 26.7 (200, 7.9) 2500 27.3 (205, 8.1) 3000 28 (210, 8.3) 3500 29.5 (221.5, 8.7) 4000 31.3 (235, 9.3) 4500 32.7 (245.5, 9.7) 5000 34.1 (256, 10.1) 5500 38.2 (286.5, 11.3) 6000 44 (330, 13) 6500 49.5 (371.5, 14.6) 6700 53.3 (400, 15.7)
MT model (Tumble generator valve open) Vehicle speed < 64 km/h (39.8 MPH)
rpm kPa (mmHg, inHg) 700 27.3 (205, 8.1) 1000 23.3 (175, 6.9) 1500 23.6 (177, 7) 2000 23.3 (175, 6.9) 2500 24 (180, 7.1) 3000 24.4 (183, 7.2) 3500 28.8 (216, 8.5) 4000 30 (225, 8.9) 4500 31.6 (237, 9.3) 5000 32.5 (244, 9.6) 5500 37.1 (278, 10.9) 6000 41.9 (314, 12.4) 6500 46.9 (352, 13.9) 6700 51.1 (383, 15.1)

rpm kPa (mmHg, inHg) 700 25.1 (188, 7.4) 1000 24.8 (186, 7.3) 1500 25.6 (192, 7.6) 2000 40 (300, 11.8) 2500 40.8 (306, 12) 3000 42.1 (316, 12.4) 3500 44 (330, 13) 4000 44.5 (334, 13.1) 4500 47.3 (355, 14) 5000 54.7 (410, 16.1) 5500 54.7 (410, 16.1) 6000 54.7 (410, 16.1) 6500 54.7 (410, 16.1) 6700 54.7 (410, 16.1)
MT model (Tumble generator valve closed) Vehicle speed < 64 km/h (39.8 MPH)
rpm kPa (mmHg, inHg) 700 27.3 (205, 8.1) 1000 23.3 (175, 6.9) 1500 23.6 (177, 7) 2000 23.3 (175, 6.9) 2500 24 (180, 7.1) 3000 24.4 (183, 7.2) 3500 28.8 (216, 8.5) 4000 30 (225, 8.9) 4500 31.6 (237, 9.3) 5000 32.5 (244, 9.6) 5500 37.1 (278, 10.9) 6000 41.9 (314, 12.4) 6500 46.9 (352, 13.9) 6700 51.1 (383, 15.1)

rpm kPa (mmHg, inHg) 700 25.1 (188, 7.4) 1000 24.8 (186, 7.3) 1500 25.6 (192, 7.6) 2000 40 (300, 11.8) 2500 40.8 (306, 12) 3000 42.1 (316, 12.4) 3500 44 (330, 13) 4000 44.5 (334, 13.1) 4500 47.3 (355, 14) 5000 54.7 (410, 16.1) 5500 54.7 (410, 16.1) 6000 54.7 (410, 16.1) 6500 54.7 (410, 16.1) 6700 54.7 (410, 16.1)
GD(H4DOTC)-81

GENERAL DESCRIPTION

(A)
#3
#2
#4
#1
#3
#2
#4
#1
#3
#2
(B)
omg7
omg6
omg5
omg4
omg3
omg2
omg1
omg0
EN-01774
(A)
Ignition order
(B)
GD(H4DOTC)-82

GENERAL DESCRIPTION

domg180 Threshold valve (positive number)
domg180
Threshold valve (negative number)
Judged as misfire.
EN-02877

Diagnostic value domg 360 = (omg 1 omg 0) (omg 3 omg 2) Misfire judgment domg 360 > Judgement value o Judge as misfire
domg360 Threshold valve
domg360
Judged as misfire.
EN-03273
GD(H4DOTC)-83

GENERAL DESCRIPTION

domg720
Threshold valve
domg720
Judged as misfire.
EN-03274
Malfunction Criteria FTP emission judgment value Threshold Value t 20 100/2000% in 1000 revs.
Malfunction Criteria FTP emission judgment value Threshold Value < 20 100/2000% in 1000 revs.
GD(H4DOTC)-84

GENERAL DESCRIPTION
Malfunction Criteria Catalyst damage misfire judgment value Threshold Value t Value from Map 3
Map 3
0.2 (0.01) 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700 148 148 140 128 116 108 98 69 60 55 54 52 50 50 0.4 (0.01) 128 128 118 90 87 87 74 61 55 55 54 52 50 50 0.6 (0.02) 116 114 102 90 57 58 43 40 34 34 33 32 30 30 0.8 (0.03) 106 104 90 73 45 39 27 27 25 23 22 21 20 20 Intake air (g(oz)/rev) 1 1.2 (0.04) (0.04) 100 92 85 58 39 36 23 22 20 20 20 20 20 20 90 85 85 43 36 36 22 20 20 20 20 20 20 20 1.4 (0.05) 90 85 85 40 34 32 20 20 20 20 20 20 20 20 1.6 (0.06) 90 85 72 36 32 30 20 20 20 20 20 20 20 20 1.8 (0.06) 90 85 72 32 30 28 20 20 20 20 20 20 20 20 2 (0.07) 90 85 72 20 20 20 20 20 20 20 20 20 20 20
Engine speed (rpm)
Malfunction Criteria Catalyst damage misfire judgment value Threshold Value < Value from Map 3

NOTE: For the detection standard, refer to DTC P0301. <Ref. to GD(H4DOTC)-80, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>


GD(H4DOTC)-85

GENERAL DESCRIPTION
AW:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(A) (1) (2)
3. ENABLE CONDITION

GD(H4DOTC)-86

GENERAL DESCRIPTION
AX:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(A) (1) (2)
3. ENABLE CONDITION

GD(H4DOTC)-87

GENERAL DESCRIPTION
AY:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

50 CA (A)
50 CA
50 CA
50 CA (B) #1BTDC10 CA (C) #3BTDC10 CA #2BTDC10 CA
50 CA
50 CA
#4BTDC10 CA
#1BTDC10 CA
10 CA
30 CA 30 CA
EN-03269
(A)
Camshaft signal (RH)
(B)
Camshaft signal (LH)
(C)
Crankshaft signal
(1)
(3)
(2)
EN-01780
(1)
(2)
Crank sprocket
(3)
3. ENABLE CONDITION

GD(H4DOTC)-88

GENERAL DESCRIPTION
GD(H4DOTC)-89

GENERAL DESCRIPTION
AZ:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE

50 CA (A)
50 CA
50 CA
50 CA
50 CA
#4BTDC10 CA
#1BTDC10 CA
10 CA
30 CA 30 CA
EN-03269
(A)
(B)
(C)
Crankshaft signal
(1)
(3)
(2)
EN-01780
(1)
(2)
Crank sprocket
(3)
3. ENABLE CONDITION
GD(H4DOTC)-90

GENERAL DESCRIPTION

Malfunction Criteria Cylinder number identification Amount of crank sensor signal during 1 rev. Threshold Value Completed Not = 30
GD(H4DOTC)-91

GENERAL DESCRIPTION
BA:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

(D)
50 CA (A)
50 CA
50 CA
50 CA
50 CA
#4BTDC10 CA
#1BTDC10 CA
10 CA
30 CA 30 CA EN-01853
(A) (B)
Camshaft signal (RH) Camshaft signal (LH)
(C)
Crankshaft signal
(D)
Number of camshaft position signals = When normal, there will be 3 cam signals for every 2 engine revolutions.
3. ENABLE CONDITION
Secondary Parameters Battery voltage Enable Conditions t8V

GD(H4DOTC)-92

GENERAL DESCRIPTION
Abnormality Judgement 1 Judge as NG when the condition where the number of camshaft position sensor signals are less than 3 time(s) during 2 engine revs. continues. Judgement Value
Malfunction Criteria Amount of camshaft sensor signal during 2 revs. Threshold Value < 3 time(s)
Time Needed for Diagnosis: Two engine revolutions 50 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement 1 Judge as OK and clear the NG when the malfunction criteria below are met. Judgement Value
Malfunction Criteria Camshaft position sensor signal Threshold Value t 3 time(s)
Time Needed for Diagnosis: Two engine revolutions Abnormality Judgement 2 If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Starter Camshaft position sensor signal Threshold Value ON No input
Time Needed for Diagnosis: 3000 ms Normality Judgement 2 Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Camshaft position sensor signal Threshold Value Input exists
BB:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

NOTE: For the detection standard, refer to DTC P0340. <Ref. to GD(H4DOTC)-92, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-93

GENERAL DESCRIPTION
BC:DTC P0410 SECONDARY AIR INJECTION SYSTEM

Detect NG judging from secondary air delivery pipe pressure, pulse of secondary air delivery pipe pressure and secondary air pipe airflow amount.
2. ENABLE CONDITION
Secondary Parameters Pump supply pressure check Estimate ambient temperature Battery voltage Barometric pressure Engine Amount of intake air Secondary air pump Combination valve Enable Conditions t 4.4 C t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) In operation t 2 g/s (0.07 oz/s) Operating Bank open (Except with both banks closed)
Combination valve both closed pulse diagnosis Estimate ambient temperature Battery voltage Barometric pressure Engine Engine load After fuel cut Combination valve changeover pressure diagnosis Estimate ambient temperature Battery voltage Barometric pressure Engine Amount of intake air
t 4.4 C t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) In operation t 0.2 g/rev (0.01 oz/rev) t 1000 ms
Engine speed After fuel cut Overflow diagnosis Estimate ambient temperature Battery voltage Barometric pressure Engine
t 4.4 C t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) In operation > 2 g/s (0.07 oz/s) and < 25 g/s (0.88 oz/s) < 4000 rpm t 1000 ms t 4.4 C t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) In operation

Perform diagnosis during secondary air pump operation
GD(H4DOTC)-94

GENERAL DESCRIPTION
Measure secondary air delivery pipe pressure, pulse of secondary air delivery pipe pressure and secondary air pipe airflow amount.
ON (1) OFF
(2)
ON (3) OFF
OPEN (4) CLOSE
OPEN (5) CLOSE (12) (11) (6) (13)
(10)
(7)
(8)
(9) EN-05591
(1) (2) (3) (4) (5) (6)
IG Ne Secondary air pump operating status E-COMB valve (right hand) status E-COMB valve (left hand) status Secondary air delivery pipe pressure (psi)
(7) (8) (9) (10)
Diagnosis enable condition Pump supply pressure check (judgment) Flow amount check (judgment) Barometric pressure (Pas) measurement before secondary air control
(11) (12) (13)
Right bank all closed pressure (POR) measurement Both banks all closed pressure (PORL) measurement Left bank all closed pressure (POL) measurement
GD(H4DOTC)-95

GENERAL DESCRIPTION
Pump supply pressure check Perform the system function diagnosis with how much the pressure rises when the secondary air pump is turned from OFF to ON. Judge as NG if delivery pipe pressure does not rise though it should when the secondary air pump turns OFF o ON. Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Threshold Value Secondary air supply pipe pressure < 0.9 kPa (7 mmHg, (after barometric pressure compensation) 0.3 inHg) DTC P0410
Time Needed for Diagnosis: 1984 ms + 2816 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Threshold Value Secondary air supply pipe pressure t 0.9 kPa (7 mmHg, (after barometric pressure compensation) 0.3 inHg) DTC P0410
Time Needed for Diagnosis: 1984 ms + 2816 ms Combination valve both closed pulse diagnosis Perform open stuck diagnosis of both combination valves using delivery pipe pressure pulse when both combination valves are closed. Determine which side of valves is stuck open by comparing secondary air flow amount when RH combination valve is closed with that when LH combination valve is closed. Calculate voltage pulse of the pump supply pipe pressure when both combination valves are closed. The calculation should be small because there is no pulse from supply pipe pressure with both combination valves closed. When the calculation is large, determine that either of the combination valves is stuck open. Determine which side of valves is stuck open by comparing secondary air flow amount when the RH combination valve is closed with that when the LH combination valve is closed. Air flow amount is larger on the open stuck valve. Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Pulse calculation value when both combination valves are closed Air flow amount when the right bank is closed (value from Map 2) Pulse calculation value when both combination valves are closed Air flow amount when the left bank is closed (value from Map 3) Threshold Value > Value of Map 1 t Air flow amount when the left bank is closed (value from Map 3) > Value of Map 1 > Air flow amount when the right bank is closed (value from Map 2) DTC P2440
P2442
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4DOTC)-96

GENERAL DESCRIPTION
Malfunction Criteria Pulse calculation value when both combination valves are closed Threshold Value d Value of Map 1 DTC P2440, P2442
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms Combination valve changeover pressure diagnosis Perform the RH combination valve stuck closed diagnosis with the variation of delivery pipe pressure when the RH combination valve turns closed o open. Delivery pipe pressure should vary when the RH combination valve turns closed o open. When the variation is small, determine that the RH combination valve is stuck closed. Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Pressure variation value when the RH combination valve is switched Threshold Value < Value of Map 4 DTC P2441
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Pressure variation value when the RH combination valve is switched Threshold Value t Value of Map 4 DTC P2441
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms Perform the LH combination valve stuck closed diagnosis with the variation of delivery pipe pressure when the LH combination valve turns open o closed. Delivery pipe pressure should vary when the LH combination valve turns open o closed. When the variation is small, determine that the LH combination valve is stuck closed. Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Pressure variation value when the LH combination valve is switched Threshold Value < Value of Map 5 DTC P2443
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4DOTC)-97

GENERAL DESCRIPTION
Malfunction Criteria Pressure variation value when the LH combination valve is switched Threshold Value t Value of Map 5 DTC P2443
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms Overflow diagnosis Perform secondary air system flow abnormality diagnosis using both sides of combination valves secondary air amount when both are closed. Judge as secondary air system flow abnormality either if there is excessive secondary air flow amount with the RH combination valve closed, or if there is excessive secondary air flow amount with the LH combination valve closed. Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Air flow amount when the right bank is closed (value from Map 2) or Air flow amount when the left bank is closed (value from Map 3) Voltage at PORL measurement Voltage at POR measurement Voltage at PORL measurement Voltage at POL measurement PORL: Both banks all closed pressure POR: Right bank all closed pressure POL: Left bank all closed pressure Threshold Value > Value of Map 6 DTC P0411
> Value of Map 7
d4V d4V
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Air flow amount when the right bank is closed (value from Map 2) or Air flow amount when the left bank is closed (value from Map 3) Voltage at PORL measurement Voltage at POR measurement Voltage at PORL measurement Voltage at POL measurement PORL: Both banks all closed pressure POR: Right bank all closed pressure POL: Left bank all closed pressure Threshold Value d Value of Map 6 DTC P0411
d Value of Map 7
d4V d4V
Time Needed for Diagnosis: 4000 ms + 992 ms + 992 ms + 992 ms
GD(H4DOTC)-98

GENERAL DESCRIPTION
Map1
Intake air (g (oz)/rev) Threshold value (V) 0.1 (0) 13 0.25 (0.01) 13 0.3 (0.01) 3.25 1 (0.04) 3.25
Map2
Secondary air pressure in the pipe when both comb. valve is closing kPa (mmHg, inHg) Secondary air pressure in the pipe when LH comb. valve is closing kPa (mmHg, inHg) 69.3 (520, 20.5) 74.6 (560, 22) 80 (600, 23.6) 85.3 (640, 25.2) 90.6 (680, 26.8) 96 (720, 28.3) 101.3 (760, 29.9) 106.6 (800, 31.5) 112 (840, 33.1) 117.3 (880, 34.6) 122.6 (920, 36.2) 128 (960, 37.8) 133.3 (1000, 39.4) 138.6 (1040, 40.9) 144 (1080, 42.5) 149.3 (1120, 44.1)
69.3 74.6 80 85.3 90.6 96 101.3 106.6 112 117.3 122.6 128 133.3 138.6 144 149.3 (520, (560, (600, (640, (680, (720, (760, (800, (840, (880, (920, (960, (1000, (1040, (1080, (1120, 20.5) 22) 23.6) 25.2) 26.8) 28.3) 29.9) 31.5) 33.1) 34.6) 36.2) 37.8) 39.4) 40.9) 42.5) 44.1)
0 200
200 0
400 200 0
600 400 200 0
800 600 400 200 0
1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 2400 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 800 600 400 200 0 1000 1200 1400 1600 1800 2000 800 600 400 200 0 1000 1200 1400 1600 1800 800 600 400 200 0 1000 1200 1400 1600 800 600 400 200 0 1000 1200 1400 800 600 400 200 0 1000 1200 800 600 400 200 0 1000 800 600 400 200 0 (L/min)
400 200
600 400 200
800 600 400 200
1000 800 600 400 200
1200 1000 800 600 400 200
1400 1200 1000 800 600 400 200
1600 1400 1200 1000 800 600 400 200
1800 1600 1400 1200 1000 800 600 400 200
2000 1800 1600 1400 1200 1000 800 600 400 200
2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
GD(H4DOTC)-99

GENERAL DESCRIPTION
Map 3
Secondary air pressure in the pipe when both comb. valve is closing kPa (mmHg, inHg) Secondary air pressure in the pipe when RH comb. valve is closing kPa (mmHg, inHg) 69.3 (520, 20.5) 74.6 (560, 22) 80 (600, 23.6) 85.3 (640, 25.2) 90.6 (680, 26.8) 96 (720, 28.3) 101.3 (760, 29.9) 106.6 (800, 31.5) 112 (840, 33.1) 117.3 (880, 34.6) 122.6 (920, 36.2) 128 (960, 37.8) 133.3 (1000, 39.4) 138.6 (1040, 40.9) 144 (1080, 42.5) 149.3 (1120, 44.1)
69.3 74.6 80 85.3 90.6 96 101.3 106.6 112 117.3 122.6 128 133.3 138.6 144 149.3 (520, (560, (600, (640, (680, (720, (760, (800, (840, (880, (920, (960, (1000, (1040, (1080, (1120, 20.5) 22) 23.6) 25.2) 26.8) 28.3) 29.9) 31.5) 33.1) 34.6) 36.2) 37.8) 39.4) 40.9) 42.5) 44.1)
0 200
200 0
400 200 0
600 400 200 0
800 600 400 200 0
1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 2400 2400 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 2400 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 2400 800 600 400 200 0 1000 1200 1400 1600 1800 2000 2200 800 600 400 200 0 1000 1200 1400 1600 1800 2000 800 600 400 200 0 1000 1200 1400 1600 1800 800 600 400 200 0 1000 1200 1400 1600 800 600 400 200 0 1000 1200 1400 800 600 400 200 0 1000 1200 800 600 400 200 0 1000 800 600 400 200 0 (L/min)
400 200
600 400 200
800 600 400 200
1000 800 600 400 200
1200 1000 800 600 400 200
1400 1200 1000 800 600 400 200
1600 1400 1200 1000 800 600 400 200
1800 1600 1400 1200 1000 800 600 400 200
2000 1800 1600 1400 1200 1000 800 600 400 200
2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
2400 2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200
GD(H4DOTC)-100

GENERAL DESCRIPTION
Map4
Amount of intake air when RH comb. valve switches (g (oz)/s) Battery voltage when RH comb. valve switches (V) 11 12 13 14 10 (0.35) 0.025 0.035 0.05 0.05 15 (0.53) 0.025 0.035 0.05 0.05 20 (0.71) 0.025 0.035 0.05 0.05 25 (0.88) 0.005 0.015 0.025 0.025 26 (0.92) 0 0 0 0 (V)
Map 5
Amount of intake air when LH comb. valve switches (g (oz)/s) Battery voltage when LH comb. valve switches (V) 11 12 13 14 10 (0.35) 0.025 0.035 0.05 0.05 15 (0.53) 0.025 0.035 0.05 0.05 20 (0.71) 0.025 0.035 0.05 0.05 25 (0.88) 0.005 0.015 0.025 0.025 26 (0.92) 0 0 0 0 (V)
Map6
Amount of intake air when P0R is measuring (g (oz)/s) Battery voltage when P0R measuring (V) 11.5 12.5 13.5 14.5 15.5 2 (0.07) 345 345 345 390 420 25 (0.88) 345 345 345 390 420 (L/min)
Map7
Amount of intake air when P0L is measuring (g (oz)/s) Battery voltage when P0L measuring (V) 11.5 12.5 13.5 14.5 15.5 2 (0.07) 345 345 345 390 420 25 (0.88) 345 345 345 390 420 (L/min)
BD:DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED

NOTE: For the detection standard, refer to DTC P0410. <Ref. to GD(H4DOTC)-94, DTC P0410 SECONDARY AIR INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-101

GENERAL DESCRIPTION
BE:DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN
Judge as NG when the ECM output level differs from the actual terminal level.

Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs OFF signal Threshold Value t 10.9 V ON LOW
Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs OFF signal Threshold Value t 10.9 V ON HIGH
GD(H4DOTC)-102

GENERAL DESCRIPTION
BF:DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED

Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs ON signal Threshold Value t 10.9 V ON HIGH
Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs ON signal Threshold Value t 10.9 V ON LOW
BG:DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN
NOTE: For the detection standard, refer to DTC P0413. <Ref. to GD(H4DOTC)-102, DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
BH:DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT SHORTED
NOTE: For the detection standard, refer to DTC P0414. <Ref. to GD(H4DOTC)-103, DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-103

GENERAL DESCRIPTION
BI: DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT OPEN

Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs OFF signal Threshold Value t 10.9 V ON LOW
Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs OFF signal Threshold Value t 10.9 V ON HIGH
GD(H4DOTC)-104

GENERAL DESCRIPTION
BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

(1)
(2)
(A)
(3)
(B)
(3)
(C)
(D)
EN-01713
(A) (B) (1)
(C)
(D)
Output waveform from the front oxygen sensor Catalytic converter
(2)
(3)
GD(H4DOTC)-105

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Battery voltage Atmospheric pressure Engine coolant temperature Estimated catalyst temperature Misfire detection every 200 rotations Learning value of evaporation gas density Sub feedback Evaporative system diagnosis Time of difference (< 0.10) between actual lambda and target lambda Vehicle speed Amount of intake air Enable Conditions t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t 70 C (158 F) t 500 C (932 F) < 5 time(s) < 0.2 In operation Not in operation t 1000 ms > 60 km/h (37.3 MPH) t 10 g/s (0.35 oz/s) and < 40 g/s (1.41 oz/s) < 0.02 g/rev (0 oz/rev) Experienced after fuel cut t 200 s t5s
Engine load change every 0.5 engine revs. Rear oxygen output change from 660 mV or less to 660 mV or more Elapsed time after starting the engine Purge execution calculated time

Malfunction Criteria 6 |(ro2sadn ro2sadn1)| / 6 |(sglmdn sglmdn1)| Threshold Value > 11 (AT model) > 9 (MT model)
Malfunction Criteria 6 |(ro2sadn ro2sadn1)| / 6 |(sglmdn sglmdn1)| Threshold Value d 11 (AT model) d 9 (MT model)
GD(H4DOTC)-106

GENERAL DESCRIPTION
BK:DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW

NOTE: For the detection standard, refer to DTC P0442. <Ref. to GD(H4DOTC)-108, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-107

GENERAL DESCRIPTION
BL:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
(3) (4) (1) (2) (5)
(6) (16)
(15) (17) (8) (10) (9) (11)
(14)
(13)
(12)
(7) EN-05372
(1) (2) (3) (4) (5) (6)
Fuel gauge Intake manifold Throttle body Purge control solenoid valve Purge control solenoid valve 2 Engine control module (ECM)
(7) (8) (9) (10) (11) (12)
Canister Pressure control valve Drain valve Drain filter Shut-off valve Fuel temperature sensor
(13) (14) (15) (16) (17)
GD(H4DOTC)-108

GENERAL DESCRIPTION
0.04-inch Diagnosis
Mode Z
OK
Mode A
OK
Mode B
OK
Mode C
OK
Mode D NG
OK
Parge control solenoid velve2 blockade diagnosis
OK NG
Early OK
END
Cancel NG OK
NG
Mode Z Extend
EN-05590
Mode Mode Z (Purge control solenoid valve opening failure diagnosis) Mode A (Estimated evaporation amount) Mode B (Sealed negative pressure, large leakage judgement) Mode C (Pressure increase check, advanced OK judgement) Mode D (Negative pressure variation measurement, evaporation leakage diagnosis)
Mode Description Perform purge control solenoid valve opening failure diagnosis from the size of tank pressure variation from diagnosis start. Calculate the tank pressure change amount (P1). Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. If the tank pressure cannot be reduced, it is diagnosed as large leak. Wait until the tank pressure returns to the target (start level of P2 calculation). If the tank pressure does not become the value, make advanced OK judgement. Calculate the tank pressure variation (P2), and obtain the diagnostic value using P1 found in Mode A. Perform the evaporation diagnosis using the diagnostic value.
0 ms + 10000 ms

GD(H4DOTC)-109

GENERAL DESCRIPTION
0.02-inch Diagnosis
Mode A
OK
Mode B
OK
Mode C
OK
Mode D
OK
Mode E
EN-02871
Mode Description When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. Wait until the tank pressure returns to the target (start level of P2 calculation). Calculate the time it takes for the tank pressure to change to the Mode E shifting pressure. If the tank pressure does not change to the Mode E shifting pressure, make advanced OK judgement. Calculate the amount of evaporation (P1).
Diagnosis Period 0 Value of Map 1 0 Value of Map 2 0 20000 ms + 0 + Value from Map 2 0 0 ms + 200000 ms 0 0 ms + 200000 ms + Value from Map 3
Map1
Map2
Map 3
GD(H4DOTC)-110

GENERAL DESCRIPTION
(a) (1)
(4)
(b)
(c)
(2)
(3)
EN-01715
(a) (1) (2)
(b) (3)
Fuel tank Valve
(c) (4)
Canister Spring
GD(H4DOTC)-111

GENERAL DESCRIPTION
A (a)
B (b)
C (c)
EN-01716
(a)
(b)
(c)
Canister
A (a)
B (b)
C (c)
EN-01717
(a)
Barometric pressure
(b)
Fuel tank
(c)
Canister
GD(H4DOTC)-112

GENERAL DESCRIPTION
A (a)
B (b)
C (c)
(1) EN-01718
(a) (1)
(b)
Fuel tank
(c)
Canister
When Solenoid is ON
A (a)
B (b)
C (c)
EN-01719
(a)
Barometric pressure
(b)
Fuel tank
(c)
Canister
GD(H4DOTC)-113

GENERAL DESCRIPTION
EN-02293
3. ENABLE CONDITION
0.04-inch Diagnosis
Secondary Parameters Battery voltage Barometric pressure Total time of canister purge operation Elapsed time after starting the engine Learning value of evaporation gas density Engine speed Fuel tank pressure Intake manifold relative vacuum (relative pressure) Vehicle speed Fuel level Closed air/fuel ratio control Fuel temperature Intake air temperature Pressure change every one second Minimum pressure change value every one second Maximum pressure change value every one second Change of fuel level per 128 milliseconds Air fuel ratio Enable Conditions t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t 120000 ms t 856 s < 0.08 1050 rpm 6500 rpm t 4 kPa (30 mmHg, 1.2 inHg) t 13.3 kPa ( 100 mmHg, 3.9 inHg) t 32 km/h (19.9 MPH) 9.6 2 (2.54 US gal, 2.11 Imp gal) 54.4 2 (14.37 US gal, 11.97 Imp gal) In operation 10 C (14 F) 45 C (113 F) t 10 C (14 F) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < 2 2 (0.53 US gal, 0.44 Imp gal) 0.76 1.25
GD(H4DOTC)-114

GENERAL DESCRIPTION
0.02-inch Diagnosis
Secondary Parameters At starting a diagnosis Evap. diagnosis Battery voltage Barometric pressure Time since last incomplete 0.02-inch leakage diagnosis When cancelling in mode A When cancelling in other than mode A Total time of canister purge operation Elapsed time after starting the engine Fuel temperature Fuel level Intake manifold relative vacuum (relative pressure) Fuel tank pressure Vehicle speed Closed air/fuel ratio control Engine speed During diagnosis Change of fuel level Pressure change every one second Minimum pressure change value every one second Maximum pressure change value every one second | Pressure change in tank every second | Barometric pressure change Enable Conditions Incomplete t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg)
> 120000 ms > 600000 ms t 120000 ms t 120 s 10 C (14 F) 55 C (131 F) 9.6 2 (2.54 US gal, 2.11 Imp gal) 54.4 2 (14.37 US gal, 11.97 Imp gal) t 13.3 kPa ( 100 mmHg, 3.9 inHg) 0.4 kPa (3.2 mmHg, 0.1 inHg) 1.4 kPa (10.7 mmHg, 0.4 inHg) 50 km/h (31.1 MPH) 510 km/h (316.9 MPH) continues for 125000 ms In operation 1050 rpm 6000 rpm d Value of Map 4 < 0.1 kPa (0.44 mmHg, 0 inHg) < 0.1 kPa (0.51 mmHg, 0 inHg) (Mode D) d 0.1 kPa (0.75 mmHg, 0 inHg) 0.5 kPa (3.6 mmHg, 0.1 inHg) 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode D) 0.3 kPa (2.4 mmHg, 0.1 inHg) 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode E)
Map4

GD(H4DOTC)-115

GENERAL DESCRIPTION
Purge control solenoid valve stuck open fault diagnosis DTC P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Purpose of Mode Z When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled. Diagnostic method Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z. Abnormality Judgement If OK judgement cannot be made, extend Mode Z, and Judge as NG when the following conditions are established after predetermined amount of time. Judgement Value
Malfunction Criteria evptez evptezha evptezini Time of 2 2 (0.53 US gal, 0.44 Imp gal) or more fuel no sloshing Threshold Value > 0.6 kPa (4.5 mmHg, 0.2 inHg) d 1.4 kPa (10.7 mmHg, 0.4 inHg) t 40000 ms DTC P0457
Time Needed for Diagnosis: 0 ms + 3000 ms + 13000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. When judgement for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis. Cancel the evaporative diagnosis when the OK/NG judgement for purge control solenoid valve stuck open cannot be made in Mode Z. Normality Judgement Judge as OK and change to Mode A when the following conditions are established after predetermined time has passed since Mode Z started. Judgement Value
Malfunction Criteria evptez evptezha Threshold Value d 0.4 kPa (3 mmHg, 0.1 inHg) DTC P0457
GD(H4DOTC)-116

GENERAL DESCRIPTION
Normal
(1)
(2)
(3) 0 (4)
(5) EN-02869
(1) (2)
Mode Z 3000 ms
(3) (4)
(5)
OK judgement
GD(H4DOTC)-117

GENERAL DESCRIPTION
(1) (3) (6) evptez
(2)
(4) 0
evptezini
(5)
evptezha
(7)
(8)
EN-02870
(1) (2) (3)
(4) (5) (6)
(7) (8)
40000 ms no fuel sloshing NG judgement
GD(H4DOTC)-118

GENERAL DESCRIPTION
Leak Diagnosis DTC P0441 Evaporative emission system incorrect purge flow P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. The diagnosis is divided into the following five phases. Mode A: (Estimated evaporation gas amount) Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B. Mode B: (Negative pressure sealed) Introduce negative pressure in the intake manifold to the tank. Approx. 0 o 1.4 kPa (0 o 10.5 mmHg, 0 o 0.4 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage in the system and terminate the evaporative emission control system diagnosis. Abnormality Judgement Judge as NG (large leakage) when the following conditions are established. Judgement Value
Malfunction Criteria Time to reach target negative pressure or Mode B time (Min. pressure value in tank when in mode B) (Tank pressure when mode B started) Threshold Value DTC t 10000 ms + 25000 ms P0457 t 10000 ms > 0.3 kPa (2.5 mmHg, 0.1 inHg)
Tank pressure when starting calTime for advanced OK culation of P2 judgement 1.3 kPa (9.75 mmHg, 0.4 inHg) 17000 ms
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 17000 ms Mode D: (Measure amount of negative pressure change) Monitor the tank pressure change amount when using mode D. In this case, the tank pressure increases, (nears barometric pressure) because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2. After calculating P2, perform a small leak diagnosis according to the items below. When Mode D is ended Assign tank variations measured in Mode A and Mode D, P1 and P2, to the formula below, judge small leaks in the system. If the measured judgement value exceeds the threshold value, it is judged to be a malfunction.
GD(H4DOTC)-119

GENERAL DESCRIPTION
Abnormality Judgement Judge as NG when the following conditions are established within the predetermined time. Judge as OK and clear the NG if the following conditions are not established within the predetermined time. Judgement Value

Fuel temperature vs. Fuel level 25 C (77 F) 30 C (86 F) 35 C (95 F) 40 C (104 F) 45 C (113 F) 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0 2 (0 US gal, 0 Imp gal) (2.1 mmHg, (2.2 mmHg, (2.3 mmHg, (2.35 mmHg, (2.4 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 10 2 (2.64 US gal, 2.2 Imp gal) (2.1 mmHg, (2.2 mmHg, (2.3 mmHg, (2.35 mmHg, (2.4 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 20 2 (5.28 US gal, 4.4 Imp gal) (2.3 mmHg, (2.4 mmHg, (2.5 mmHg, (2.6 mmHg, (2.7 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 30 2 (7.93 US gal, 6.6 Imp gal) (2.9 mmHg, (3.05 mmHg, (3.15 mmHg, (3.25 mmHg, (3.35 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.4 kPa 0.4 kPa 0.4 kPa (3.4 mmHg, (3.5 mmHg, 40 2 (10.57 US gal, 8.8 Imp gal) (2.9 mmHg, (3.15 mmHg, (3.3 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.4 kPa 0.4 kPa 0.5 kPa (3.5 mmHg, (3.6 mmHg, (3.7 mmHg, 50 2 (13.21 US gal, 11 Imp gal) (3.2 mmHg, (3.3 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.5 kPa 60 2 (15.85 US gal, 13.2 Imp gal) (3.2 mmHg, (3.3 mmHg, (3.5 mmHg, (3.6 mmHg, (3.7 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg)
Purge control solenoid valve 2 stuck close diagnosis Perform purge control solenoid valve 2 stuck close diagnosis using the variation gap between the tank pressure at the end of mode C and after mode C.
Malfunction Criteria Elapsed time after completion of mode C advanced OK judgement Tank pressure variation after completion of mode C advanced OK judgement Threshold Value = 3500 ms < 0.758 mmHg DTC P0441
GD(H4DOTC)-120

GENERAL DESCRIPTION
Leak Diagnosis DTC P0456 Evaporative Emission Control System Leak Detected (very small leak) The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. The diagnosis is divided into the following five phases. Mode A: (0 point compensation) When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Shift to mode B when returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time. Mode B: (Negative pressure introduced) Introduce negative pressure in the intake manifold to the tank. Approx. 0 o 2 kPa (0 o 15 mmHg, 0 o 0.6 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. When the tank internal pressure does not reach the target vacuum pressure, the diagnosis is cancelled. Mode C: (Negative pressure maintained) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed. Mode D: (Calculate the amount of negative pressure change) Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time (evpdset) for the tank pressure to change to the Mode E shifting pressure. When the Mode E shifting pressure is reached, Mode E is entered. If it does not change to the Mode E shifting pressure after the predetermined amount of time has passed, make advanced OK judgement or cancel the diagnosis. Normality Judgement Judge as OK when the following conditions are established. Judgement Value
Malfunction Criteria Advanced OK judgement 1 Mode D time Tank internal pressure Advanced OK judgement 2 Mode D time P2 Threshold Value t 0 ms + 20000 ms d Value of Map 6 t 0 ms + 200000 ms d Value of Map 7
Map6
Map7
GD(H4DOTC)-121

GENERAL DESCRIPTION
Malfunction Criteria P1 Threshold Value < Value of Map 8
Map 8 Fault criteria limit for Evaporative emission control system diagnosis
Time (evpdset) vs Fuel level 0 2 (0 US gal, 0 Imp gal) 0 ms 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 30000 ms 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 50000 ms 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.85 mmHg, 0.1 inHg) 0.3 kPa (2 mmHg, 0.1 inHg) 0.3 kPa (2 mmHg, 0.1 inHg) 100000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 160000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 200000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg)
10 2 (2.64 US gal, 2.2 Imp gal)
20 2 (5.28 US gal, 4.4 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)
40 2 (10.57 US gal, 8.8 Imp gal)
50 2 (13.21 US gal, 11 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
Time Needed for Diagnosis:Value of Map1+ Value of Map2 + 20000 ms + 0 + Value of Map2 + 0 ms + 200000 ms + Value of Map3 + 0 ms + 200000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4DOTC)-122

GENERAL DESCRIPTION
Malfunction Criteria P1 Threshold Value > Value of Map 9

Time (evpdset) vs Fuel level 0 2 (0 US gal, 0 Imp gal) 0 ms 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 30000 ms 0.5 kPa (3.5 mmHg, 0.1 inHg) 0.5 kPa (3.5 mmHg, 0.1 inHg) 0.4 kPa (3.25 mmHg, 0.1 inHg) 0.4 kPa (3 mmHg, 0.1 inHg) 0.3 kPa (2.25 mmHg, 0.1 inHg) 0.2 kPa (1.5 mmHg, 0.1 inHg) 0.2 kPa (1.5 mmHg, 0.1 inHg) 50000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 100000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 160000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 200000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg)
10 2 (2.64 US gal, 2.2 Imp gal)
20 2 (5.28 US gal, 4.4 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)
40 2 (10.57 US gal, 8.8 Imp gal)
50 2 (13.21 US gal, 11 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
Time Needed for Diagnosis:Value of Map1+ Value of Map2 + 20000 ms + 0 + Value of Map2 + 0 ms + 200000 ms + Value of Map3 + 0 ms + 200000 ms
GD(H4DOTC)-123

GENERAL DESCRIPTION
BM:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION

GD(H4DOTC)-124

GENERAL DESCRIPTION
GD(H4DOTC)-125

GENERAL DESCRIPTION
BN:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION

GD(H4DOTC)-126

GENERAL DESCRIPTION
GD(H4DOTC)-127

GENERAL DESCRIPTION
BO:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION

GD(H4DOTC)-128

GENERAL DESCRIPTION
< 0 kPa (0.375 mmHg, 0 inHg) t 7 C (44.6 F)
If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is less than 2 2 (0.53 US gal, 0.44 Imp gal), extend 60 s and make judgement with the Max. and Min. values for the fuel level in 60 s 2. 60 s If a difference does not appear, extend the time (60 s 3, 60 s 4, 60 s 5) and continue the judgement. If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more, the diagnosis counter counts up. Time Needed for Diagnosis: 60 s 16 time(s) or more Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
GD(H4DOTC)-129

GENERAL DESCRIPTION
BP:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION

GD(H4DOTC)-130

GENERAL DESCRIPTION
Malfunction Criteria Fuel tank pressure Battery voltage Threshold Value < 7.4 kPa (55.85 mmHg, 2.2 inHg) t 10.9 V
Malfunction Criteria Fuel tank pressure Battery voltage Threshold Value t 7.4 kPa (55.85 mmHg, 2.2 inHg) t 10.9 V
GD(H4DOTC)-131

GENERAL DESCRIPTION
BQ:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION

GD(H4DOTC)-132

GENERAL DESCRIPTION
Malfunction Criteria Fuel tank pressure Fuel temperature Barometric pressure Threshold Value t 8 kPa (59.85 mmHg, 2.4 inHg) < 35 C (95 F) t 75 kPa (563 mmHg, 22.2 inHg)
Malfunction Criteria Fuel tank pressure Threshold Value < 8 kPa (59.85 mmHg, 2.4 inHg)
BR:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
BS:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
GD(H4DOTC)-133

GENERAL DESCRIPTION
BT:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
(B) (A)
EN-02197
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION

GD(H4DOTC)-134

GENERAL DESCRIPTION
Malfunction Criteria Duty ratio of ON Terminal output voltage Threshold Value < 0.75 Low
GD(H4DOTC)-135

GENERAL DESCRIPTION
BU:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
(B) (A)
EN-02197
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION

GD(H4DOTC)-136

GENERAL DESCRIPTION
Malfunction Criteria Duty ratio of ON Terminal output voltage Threshold Value t 0.25 High
GD(H4DOTC)-137

GENERAL DESCRIPTION
BV:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

(A)
(B)
EN-01734
(A)
Fuel level
(B)
Resistance
3. ENABLE CONDITION

GD(H4DOTC)-138

GENERAL DESCRIPTION
Malfunction Criteria Accumulated amount of intake air Max. min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine Threshold Value t 330957 g (11672.85 oz) < 2.6 2 (0.69 US gal, 0.57 Imp gal) t 10.9 V < 6500 rpm t 5000 ms
Malfunction Criteria Accumulated amount of intake air Max. min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine Threshold Value t 330957 g (11672.85 oz) t 2.6 2 (0.69 US gal, 0.57 Imp gal) t 10.9 V < 6500 rpm t 5000 ms
GD(H4DOTC)-139

GENERAL DESCRIPTION
BW:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

(1)
(5)
(4)
(2)
(3)
EN-05371
(1) (2)
(3) (5)
Fuel sub level sensor Body integrated unit
(4)
Detecting circuit
3. ENABLE CONDITION

GD(H4DOTC)-140

GENERAL DESCRIPTION
GD(H4DOTC)-141

GENERAL DESCRIPTION
BX:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

(1)
(5)
(4)
(2)
(3)
EN-05371
(1) (2)
(3) (5)
(4)
Detecting circuit
3. ENABLE CONDITION

GD(H4DOTC)-142

GENERAL DESCRIPTION
GD(H4DOTC)-143

GENERAL DESCRIPTION
BY:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

2. ENABLE CONDITION

GD(H4DOTC)-144

GENERAL DESCRIPTION
Diagnosis condition
(A)
Diagnosis timer
(C) (D)
(B) EN-05569
(A) (B)
(C)
Malfunction
(D)
Normal
GD(H4DOTC)-145

GENERAL DESCRIPTION
Map
Maximum value Minimum value of change of tank pressure for 12288 ms Maximum value Minimum value of battery voltage for12288 ms t 0 kPa (0.375 mmHg, 0 inHg) t 0.969 V
GD(H4DOTC)-146

GENERAL DESCRIPTION
BZ:DTC P0500 VEHICLE SPEED SENSOR A

3. ENABLE CONDITION

GD(H4DOTC)-147

GENERAL DESCRIPTION
CA:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
2. ENABLE CONDITION

GD(H4DOTC)-148

GENERAL DESCRIPTION
CB:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION

GD(H4DOTC)-149

GENERAL DESCRIPTION
CC:DTC P0512 STARTER REQUEST CIRCUIT

2. ENABLE CONDITION

Malfunction Criteria Engine condition Starter OFF signal Battery voltage Threshold Value After engine starting Not detected t8V
Malfunction Criteria Starter OFF signal Battery voltage Threshold Value Detected t8V
GD(H4DOTC)-150

GENERAL DESCRIPTION
CD:DTC P0513 INCORRECT IMMOBILIZER KEY

DTC P0513 P1570 P1571 P1572 P1574 P1576 P1577 P1578 Item Incorrect Immobilizer Key Antenna Reference Code Incompatibility IMM Circuit Failure (Except Antenna Circuit) Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Outline of Diagnosis Incorrect immobilizer key (Use of unregistered key in body integrated unit) Faulty antenna Reference code incompatibility between body integrated unit and ECM Communication failure between body integrated unit and ECM Failure of body integrated unit to verify key (transponder) ID code or transponder failure ECM malfunctioning Body integrated unit malfunctioning Reference code incompatibility between body integrated unit and combination meter
2. ENABLE CONDITION

GD(H4DOTC)-151

GENERAL DESCRIPTION
CE:DTC P0600 SERIAL COMMUNICATION LINK

3. ENABLE CONDITION

GD(H4DOTC)-152

GENERAL DESCRIPTION
GD(H4DOTC)-153

GENERAL DESCRIPTION
CF:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
2. ENABLE CONDITION

Malfunction Criteria Write the specified value to RAM and then read. Threshold Value The written value cannot be read.
Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria Write the specified value to RAM and then read. Threshold Value The written value can be read.
GD(H4DOTC)-154

GENERAL DESCRIPTION
CG:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
2. ENABLE CONDITION

Time Needed for Diagnosis: Main CPU: 16 milliseconds 32 time(s) Sub CPU: 16 milliseconds 2 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Time Needed for Diagnosis: Main CPU: 16 milliseconds 125 time(s) Sub CPU: 16 milliseconds 2 time(s)
GD(H4DOTC)-155

GENERAL DESCRIPTION
CH:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE

Judge as NG when any one of the followings is established. (1) When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU. (2) When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and sub CPU. (3) When the sub CPU operates abnormally. (4) When the communication between main CPU m o sub CPU is abnormal. (5) When the input amplifier circuit of throttle position sensor 1 is abnormal. (6) When the cruise control cannot be canceled correctly. (7) When the signal of brake SW1 and 2 is mismatched.
(12) (1)
(2) (11) (10)
(13) (10) (3)
(4) (5)
(10) (14)
(6) (10)
(7) (8) (9) EN-01862
(1) (2) (3) (4) (5)
(6) (7) (8) (9) (10)
(11) (12) (13) (14)
GD(H4DOTC)-156

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters (1) Ignition switch (1) Battery voltage (2) Ignition switch (2) Battery voltage (3) Ignition switch (3) Battery voltage (4) Ignition switch (4) Battery voltage (5) Throttle opening angle (5) Ignition switch (5) Battery voltage (6) Brake switch (only with cruise control) (6) Ignition switch (6) Battery voltage (7) Ignition switch (7) Battery voltage Enable Conditions ON t6V ON t6V ON t6V ON t6V ON t6V ON ON t6V ON t6V

(1) (4): Always perform the diagnosis continuously. (5): Always perform the diagnosis continuously when idling. (6): Perform the diagnosis when the brake pedal is depressed. (7): Always perform the diagnosis continuously.
Malfunction Criteria (1) Difference of CPU reading value of the throttle position sensor signal (2) Difference of CPU read value of the accelerator pedal position sensor signal (3) WD pulse from sub CPU (4) Communication between CPU (5) |Throttle position sensor 1 opening angle (Throttle position sensor 1 opening angle after passing amplifier) 1/4| (6) Cruise control cancel signal at brake ON (7) Brake switch 1, 2 signal Threshold Value t 0.4058 V t 0.127542424 V No WD pulse occur Not possible to communicate t3
Cruise control cancel signal OFF SW 1 and 2 are not matched
Time Needed for Diagnosis: (1): 600 ms (2): 830 ms (3): 200 ms (4): 200 ms (5): 24 ms (6): 250 ms (7): 200 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4DOTC)-157

GENERAL DESCRIPTION
Malfunction Criteria (1) Difference of CPU reading value of the throttle position sensor signal (2) Difference of CPU read value of the accelerator pedal position sensor signal (3) WD pulse from sub CPU (4) Communication between CPU Threshold Value < 0.4058 V < 0.127542424 V WD pulse occur Possible to communicate <3
(5) |Throttle position sensor 1 opening angle (Throttle position sensor 1 opening angle after passing amplifier) 1/4| (6) Cruise control cancel signal at brake Cruise control cancel ON signal ON (7) Brake switch 1, 2 signal SW 1 and 2 are matched
Time Needed for Diagnosis: (1): 2000 ms (2): 2000 ms (3): 2000 ms (4): 2000 ms (5): 24 ms (6): 2000 ms (7): 2000 ms
GD(H4DOTC)-158

GENERAL DESCRIPTION
CI: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)

(3)
(1)
(4)
(2)
EN-01863
(1) (2)
(3)
(4)
Drive circuit
3. ENABLE CONDITION
Secondary Parameters Normal operation of electronic throttle control Enable Conditions ON

GD(H4DOTC)-159

GENERAL DESCRIPTION
Malfunction Criteria Difference between target opening angle and actual opening angle Output duty to drive circuit Threshold Value t Value of Map 1 t 95%
Map1
Target throttle opening angle () = d Difference between target opening angle and actual opening angle () 0 d d < 6.15 3.5 6.15 d d < 9.65 5 9.65 d d < 14.65 12 14.65 d d < 26.65 25 26.65 d d 25
Time Needed for Diagnosis: Difference between target opening angle and actual opening angle: 1000 milliseconds (when target opening angle > actual opening angle) or value of Map 2 (when target opening angle d actual opening angle) Output duty to drive circuit: value of Map 3 Map2
Throttle position sensor 1 opening angle () = d Judgement time (milliseconds) 0 d d < 5.5 1000 5.5 d d < 9 400 9 d d < 13 300 13 d d < 22 250 22 d d 250
Map 3
Voltage to drive circuit (V) Judgement time (milliseconds) 6 2000 8 2000 10 2000 12 2000 14 2000 16 2000
Malfunction Criteria Difference between target opening angle and actual opening angle Output duty to drive circuit Threshold Value < Value of Map 1 < 95%
Time Needed for Diagnosis: Difference between target opening angle and actual opening angle: 2000 ms Output duty to drive circuit: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H4DOTC)-160

GENERAL DESCRIPTION
CJ:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

2. ENABLE CONDITION

Malfunction Criteria Battery voltage MIL lighting request from TCM Threshold Value t 10.9 V Yes
Malfunction Criteria Battery voltage MIL lighting request from TCM Threshold Value t 10.9 V None
GD(H4DOTC)-161

GENERAL DESCRIPTION
CK:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)

Detect the open or short circuit of neutral SW. Judge as NG when the neutral terminal input in ECM differs from the received data from TCM.
2. ENABLE CONDITION

Perform the diagnosis continuously after two seconds have passed since the engine started.
Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are OFF and when the other switches are ON Threshold Value LOW (ON)
Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are OFF and when the other switches are ON Threshold Value HIGH (OFF)
GD(H4DOTC)-162

GENERAL DESCRIPTION
CL:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

2. ENABLE CONDITION

Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value LOW (ON) continues. From a) to b)
Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value Changes to HIGH (OFF). From a) to b)
GD(H4DOTC)-163

GENERAL DESCRIPTION
CM:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)

2. ENABLE CONDITION

Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are ON and when the other switches are OFF Threshold Value HIGH (OFF)
Malfunction Criteria Neutral switch signal in ECM when P/ N range in TCM are ON and when the other switches are OFF Threshold Value LOW (ON)
GD(H4DOTC)-164

GENERAL DESCRIPTION
CN:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

2. ENABLE CONDITION

Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value HIGH (OFF) continues. From a) to b)
Malfunction Criteria Neutral switch signal (while changing from a to b below) Driving condition change a) Engine speed 600 rpm 900 rpm & Vehicle speed = 0 km/h (0 MPH) b) Engine speed 1600 rpm 900 rpm & Vehicle speed t 0 km/h (0 MPH) Threshold Value Changes to LOW (ON). From a) to b)
GD(H4DOTC)-165

GENERAL DESCRIPTION
CO:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
GD(H4DOTC)-166

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 180CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient Enable Conditions t 4096 ms t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) Execution 0.2 V 0.1 V On Min. On Max. t 60000 ms t 70 C (158 F) t 20 km/h (12.4 MPH) t 6 g/s (0.21 oz/s) < 0.02 g/rev (0 oz/rev) 0 : 50 : < 0.2 t 19.9 s 1 1

Malfunction Criteria O value Threshold Value < 0.85
Malfunction Criteria O value Threshold Value t 0.85
GD(H4DOTC)-167

GENERAL DESCRIPTION
CP:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
GD(H4DOTC)-168

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 180CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient Enable Conditions t 4096 ms t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) Execution 0.2 V 0.1 V On Min. On Max. t 60000 ms t 70 C (158 F) t 20 km/h (12.4 MPH) t 6 g/s (0.21 oz/s) < 0.02 g/rev (0 oz/rev) 0 : 50 : < 0.2 t 19.9 s 1 1

Malfunction Criteria O value Threshold Value > 1.15
Malfunction Criteria O value Threshold Value d 1.15
GD(H4DOTC)-169

GENERAL DESCRIPTION
CQ:DTC P1160 RETURN SPRING FAILURE

(1) (3)
(8)
(2)
S S
(7) (6) (4)
(5)
EN-04463
(1) (2) (3)
(4) (5) (6)
(7) (8)
DC motor Main and sub throttle position sensor
3. ENABLE CONDITION
Secondary Parameters Battery voltage Throttle position sensor Enable Conditions t6V Normal

GD(H4DOTC)-170

GENERAL DESCRIPTION
Malfunction Criteria Opening variation after continuity is set to OFF Threshold Value <2
Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria Opening variation after continuity is set to OFF Threshold Value t2
GD(H4DOTC)-171

GENERAL DESCRIPTION
CR:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
(1)
(A) (2) (3) (4)
(B)
(C)
(5) EN-01759
(A) (1) (2)
(B) (3) (4)
(C) (5)
To fuel tank Valve
3. ENABLE CONDITION

GD(H4DOTC)-172

GENERAL DESCRIPTION
GD(H4DOTC)-173

GENERAL DESCRIPTION
CS:DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN
Always detect abnormally that both combination valve electromagnetic valve and the reed valve are open failure. Calculate the integrated value of Max./Min. value and output voltage deviation of the secondary air delivery pipe pressure sensor output voltage in a given time after engine start. Judge as NG if the integrated value and the difference between Max. and Min. values are large.
Secondary Parameters Engine speed Enable Conditions t 500 rpm and < 10000 rpm t 9000 ms t 9000 ms t 2 g/s (0.07 oz/s) and < 400 g/s (14.11 oz/s) t 10.9 V > 0 g/rev t 1000 ms
Elapsed time after starting the engine After secondary air system stops Amount of intake air
Battery voltage Engine load After fuel cut

Perform continuous diagnosis when air flow amount is large during the secondary air pump stop after engine start.
GD(H4DOTC)-174

GENERAL DESCRIPTION
When both combination valve electromagnetic valve and the reed valve are open failure, the failure appears as pulses in the secondary air delivery pipe pressure sensor output. Detect abnormality by capturing these pulses using the following method. Abnormality Judgement Calculate Max./Min. value of the secondary air delivery pipe pressure sensor output voltage and the sum of the output voltage deviation for the given time. Compare the difference between Max. and Min. values with threshold value and also compare the sum value with the threshold value. If both values exceed the threshold value, count up NG counter and then judge as NG if the counter reaches the given times. Judgement Value
Malfunction Criteria Pipe inner pressure difference between Max. and Min. Sum of the pipe inner pressure variation value every 4 milliseconds Barometric pressure variation value Threshold Value > 0.05 V >5V < 26.7 kPa (200 mmHg, 7.9 inHg)
Time Needed for Diagnosis: 2000 ms 20 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear NG if neither exceeds the threshold value, or if either of the two exceeds the threshold value. Judgement Value
Malfunction Criteria Pipe inner pressure difference between Max. and Min. Sum of the pipe inner pressure variation value every 4 milliseconds Threshold Value d 0.05 V d5V
GD(H4DOTC)-175

GENERAL DESCRIPTION
CT:DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED


Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs ON signal Threshold Value t 10.9 V ON HIGH
Malfunction Criteria Battery voltage Ignition Terminal output voltage when ECM outputs ON signal Threshold Value t 10.9 V ON LOW
GD(H4DOTC)-176

GENERAL DESCRIPTION
CU:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
(1)
(A) (2) (3) (4)
(B)
(C)
(5) EN-01759
(A) (1) (2)
(B) (3) (4)
(C) (5)
To fuel tank Valve
3. ENABLE CONDITION

GD(H4DOTC)-177

GENERAL DESCRIPTION
GD(H4DOTC)-178

GENERAL DESCRIPTION
CV:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION

GD(H4DOTC)-179

GENERAL DESCRIPTION
Malfunction Criteria Fuel tank pressure Cumulative time when all the malfunction criteria below are met. Purge control solenoid valve duty Fuel temperature Intake manifold relative pressure Threshold Value > 4 kPa (30 mmHg, 1.2 inHg) t 30000 ms Not = 0 10 C (14 F) 55 C (131 F) t 26.7 kPa (200 mmHg, 7.9 inHg)
GD(H4DOTC)-180

GENERAL DESCRIPTION
CW:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM

Detect the blow-by hose release abnormality. Judge as NG when the diagnosis terminal voltage is high.
(1)
(4)
(2)
(3)
EN-01790
(1) (2)
Engine control module (ECM) Detecting circuit
(3)
PCV diagnosis connector
(4)
5V
3. ENABLE CONDITION

GD(H4DOTC)-181

GENERAL DESCRIPTION
Malfunction Criteria Battery voltage Engine condition Positive crankcase ventilation diagnosis voltage Threshold Value t 10.9 V After engine starting High
Malfunction Criteria Battery voltage Engine condition Positive crankcase ventilation diagnosis voltage Threshold Value t 10.9 V After engine starting Low
GD(H4DOTC)-182

GENERAL DESCRIPTION
CX:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

2. ENABLE CONDITION

GD(H4DOTC)-183

GENERAL DESCRIPTION
CY:DTC P1570 ANTENNA

NOTE: For the detection standard, refer to DTC P0513. <Ref. to GD(H4DOTC)-151, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CZ:DTC P1571 REFERENCE CODE INCOMPATIBILITY

DA:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

DB:DTC P1574 KEY COMMUNICATION FAILURE

DC:DTC P1576 EGI CONTROL MODULE EEPROM

DD:DTC P1577 IMM CONTROL MODULE EEPROM

DE:DTC P1578 METER FAILURE

GD(H4DOTC)-184

GENERAL DESCRIPTION
DF:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

2. ENABLE CONDITION

Exhaust gas temperature diagnosis Abnormality Judgement Calculate the estimated exhaust gas temperature when the diagnostic enable condition is established. Judge as NG when the following conditions are established after engine starting within the predetermined time. Judgement Value
Malfunction Criteria Estimated exhaust gas temperature Threshold Value < Value from Map
Map
Coolant temperature after starting the engine Threshold value (AT model) Threshold value (MT model) 40 C 30 C 20 C 10 C (40 F) (22 F) (4 F) (14 F) 200 C (392 F) 200 C (392 F) 200 C (392 F) 200 C (392 F) 200 C (392 F) 200 C (392 F) 0 C (32 F) 10 C (50 F) 20 C (68 F) 30 C (86 F) 40 C (104 F) 45 C (113 F)
200 C 98 C 98 C 97 C 93 C 89 C 88 C (392 F) (208.4 F) (208.4 F) (206.6 F) (199.4 F) (192.2 F) (190.4 F) 200 C 86.45830052 C 83.45699292 C 82.13981981 C 77.22136721 C 74.07767676 C 73.24222051 C (171 F) (165.3 F) (163.8 F) (392 F) (187.6 F) (182.2 F) (179.9 F)
Malfunction Criteria Estimated exhaust gas temperature Threshold Value t Value from Map
GD(H4DOTC)-185

GENERAL DESCRIPTION
Idle speed diagnosis Abnormality Judgement Judge as NG when the following conditions are established after the predetermined time. Judgement Value
Malfunction Criteria Continuous time of (Target engine speed Actual engine speed > 100 rpm) Continuous time of (actual retard amount > 30 CA) Threshold Value t 6000 ms t 0 ms
Malfunction Criteria Continuous time of (Target engine speed Actual engine speed > 100 rpm) Continuous time of (actual retard amount > 30 CA) Threshold Value < 6000 ms < 0 ms
GD(H4DOTC)-186

GENERAL DESCRIPTION
DG:DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1)

Detect the malfunction of tumble generator valve motor function. Judge open fixing malfunction when the opening degree is large even after finishing the tumble generator valve closing driving.
2. ENABLE CONDITION
Secondary Parameters Battery voltage Engine coolant temperature Ambient air temperature Enable Conditions t 10.9 V t 30 C (22 F) t 30 C (22 F)

Malfunction Criteria Tumble generator valve opening Tumble generator valve close signal output Threshold Value t 64.3 t 3200 ms
Malfunction Criteria Tumble generator valve opening Tumble generator valve close signal output Threshold Value < 64.3 t 3200 ms
GD(H4DOTC)-187

GENERAL DESCRIPTION
DH:DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2)

Detect the malfunction of tumble generator valve motor function. Judge open fixing malfunction when the opening degree is large even after finishing the tumble generator valve closing driving.
2. ENABLE CONDITION

Malfunction Criteria Tumble generator valve opening Tumble generator valve close signal output Threshold Value t 64.3 t 3200 ms
Malfunction Criteria Tumble generator valve opening Tumble generator valve close signal output Threshold Value < 64.3 t 3200 ms
GD(H4DOTC)-188

GENERAL DESCRIPTION
DI: DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1)
Detect the malfunction of tumble generator valve motor function. Judge close fixing malfunction when the opening degree is small even after finishing the tumble generator valve open driving.
2. ENABLE CONDITION

Malfunction Criteria Tumble generator valve opening Tumble generator valve open signal output Threshold Value < 64.3 t 4600 ms
Malfunction Criteria Tumble generator valve opening Tumble generator valve open signal output Threshold Value t 64.3 t 4600 ms
GD(H4DOTC)-189

GENERAL DESCRIPTION
DJ:DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2)

Detect the malfunction of tumble generator valve motor function. Judge close fixing malfunction when the opening degree is small even after finishing the tumble generator valve open driving.
2. ENABLE CONDITION

Malfunction Criteria Tumble generator valve opening Tumble generator valve open signal output Threshold Value < 64.3 t 4600 ms
Malfunction Criteria Tumble generator valve opening Tumble generator valve open signal output Threshold Value t 64.3 t 4600 ms
GD(H4DOTC)-190

GENERAL DESCRIPTION
DK:DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1)

Detect the open or short circuit of tumble generator valve motor. Judge as NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789
(1)
(2)
Tumble generator valve
(3)
Battery
3. ENABLE CONDITION

Abnormality Judgement At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON o OFF, and judge open NG when the open NG signal is sent 96 ms 20 time(s) in a row. Judgement Value
Malfunction Criteria Open NG signal input Overcurrent NG signal input Threshold Value Low High
Time Needed for Diagnosis: 96 ms 20 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG when the OK signal is sent. Judgement Value
Malfunction Criteria Open NG signal input Overcurrent NG signal input Threshold Value High High
GD(H4DOTC)-191

GENERAL DESCRIPTION
DL:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1)

Detect the open or short circuit of tumble generator valve motor. Judge as NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789
(1)
(2)
(3)
Battery
3. ENABLE CONDITION

Abnormality Judgement At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON o OFF, and judge overcurrent NG when the overcurrent NG signal is sent 96 ms 10 time(s) in a row. Judgement Value
Malfunction Criteria Open NG signal input Overcurrent NG signal input Threshold Value High Low
GD(H4DOTC)-192

GENERAL DESCRIPTION
DM:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2)

Detect the open or short circuit of tumble generator valve motor. Judge as NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789
(1)
(2)
(3)
Battery
3. ENABLE CONDITION

Abnormality Judgement At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON o OFF, and judge open NG when the open NG signal is sent 96 ms 20 time(s) in a row. Judgement Value
Malfunction Criteria Open NG signal input Overcurrent NG signal input Threshold Value Low High
GD(H4DOTC)-193

GENERAL DESCRIPTION
DN:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2)

Detect the open or short circuit of tumble generator valve motor. Judge as NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789
(1)
(2)
(3)
Battery
3. ENABLE CONDITION

Abnormality Judgement At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON o OFF, and judge overcurrent NG when the overcurrent NG signal is sent 96 ms 10 time(s) in a row. Judgement Value
Malfunction Criteria Open NG signal input Overcurrent NG signal input Threshold Value High Low
GD(H4DOTC)-194

GENERAL DESCRIPTION
DO:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1)
Detect open or short circuit of tumble generator valve position sensor. Judge as NG if out of specification.
(3)
(4) (1) (2)
EN-01768
(1) (2)
Rotor Return spring
(3)
Voltage (V)
(4)
Tumble generator valve opening ()
3. ENABLE CONDITION

GD(H4DOTC)-195

GENERAL DESCRIPTION
DP:DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1)
(3)
(4) (1) (2)
EN-01768
(1) (2)
Rotor Return spring
(3)
Voltage (V)
(4)
Throttle valve opening angle ()
3. ENABLE CONDITION

GD(H4DOTC)-196

GENERAL DESCRIPTION
DQ:DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2)
(3)
(4) (1) (2)
EN-01768
(1) (2)
Rotor Return spring
(3)
Voltage (V)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-197

GENERAL DESCRIPTION
DR:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2)
(3)
(4) (1) (2)
EN-01768
(1) (2)
Rotor Return spring
(3)
Voltage (V)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-198

GENERAL DESCRIPTION
DS:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
Detect open or short circuit of the oil flow control solenoid valve. Judge as NG when the current is small even though the duty signal is large.
2. ENABLE CONDITION

Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current Threshold Value t 10.9 V t 99.61 % < 0.306 A
Malfunction Criteria Threshold Value Battery voltage t 10.9 V Target current value of the oil flow control t 0.14 A solenoid valve |Target current value of the oil flow con< 0.08 A trol solenoid valve Oil flow control solenoid valve control current value|
GD(H4DOTC)-199

GENERAL DESCRIPTION
DT:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
Detect open or short circuit of oil flow control solenoid valve. Judge as NG when the current is large even though the duty signal is small.
2. ENABLE CONDITION

Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current Threshold Value t 10.9 V < 0.39 % t 0.306 A
Malfunction Criteria Threshold Value Battery voltage t 10.9 V |Target current value of the oil flow con< 0.08 A trol solenoid valve Oil flow control solenoid valve control current value|
GD(H4DOTC)-200

GENERAL DESCRIPTION
DU:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
NOTE: For the detection standard, refer to DTC P2088. <Ref. to GD(H4DOTC)-199, DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
DV:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
NOTE: For the detection standard, refer to DTC P2089. <Ref. to GD(H4DOTC)-200, DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-201

GENERAL DESCRIPTION
DW:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION

GD(H4DOTC)-202

GENERAL DESCRIPTION
Malfunction Criteria Sub feedback learning value Threshold Value < 0.02 (AT model) < 0.02 (MT model)
Malfunction Criteria Sub feedback learning value Threshold Value t 0.02 + 0.005 (AT model) t 0.02 + 0 (MT model)
GD(H4DOTC)-203

GENERAL DESCRIPTION
DX:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION

GD(H4DOTC)-204

GENERAL DESCRIPTION
Malfunction Criteria Sub feedback learning value Threshold Value t 0.04 (AT model) t 0.04 (MT model)
Malfunction Criteria Sub feedback learning value Threshold Value < 0.04 + 0.005 (AT model) < 0.04 + 0 (MT model)
GD(H4DOTC)-205

GENERAL DESCRIPTION
DY:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE

12V (1) 12V
(6)
(2)
(3)
(4)
(7)
(2)
(5) EN-01867
(1) (2) (3)
(4) (5)
(6) (7)
3. ENABLE CONDITION
Secondary Parameters Enable Conditions Under control of electronic throttle control ON CPU communication line sub o main Normal normal judgment

GD(H4DOTC)-206

GENERAL DESCRIPTION
Malfunction Criteria Motor current or Drive circuit inner temperature Threshold Value >8A > 175C (347F)
GD(H4DOTC)-207

GENERAL DESCRIPTION
DZ:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

12V (1) 12V
(4)
(2)
(3)
(5)
EN-01868
(1) (2)
(3) (4)
(5)
Motor
3. ENABLE CONDITION
Secondary Parameters Battery voltage Electronic throttle control relay output Enable Conditions t 11 V ON

GD(H4DOTC)-208

GENERAL DESCRIPTION
Malfunction Criteria Motor power voltage Threshold Value d5V
Malfunction Criteria Motor power voltage Threshold Value >5V
GD(H4DOTC)-209

GENERAL DESCRIPTION
EA:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

12V (1) 12V
(4)
(2)
(3)
(5)
EN-01868
(1) (2)
(3) (4)
(5)
Motor
3. ENABLE CONDITION
Secondary Parameters Battery voltage Electronic throttle control relay output Enable Conditions t6V OFF

GD(H4DOTC)-210

GENERAL DESCRIPTION
Malfunction Criteria Motor power voltage Threshold Value t5V
Malfunction Criteria Motor power voltage Threshold Value <5V
GD(H4DOTC)-211

GENERAL DESCRIPTION
EB:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE

(1)
(3)
(2)
(4)
EN-01869
(1) (2)
(3)
Motor
(4)
3. ENABLE CONDITION

GD(H4DOTC)-212

GENERAL DESCRIPTION
Malfunction Criteria Throttle sensor opening angle at full close point learning Threshold Value < 10.127 or > 19.872 or Throttle opening angle when the ignition switch is ON Throttle minimum stop position < 1.683
Time Needed for Diagnosis: 8 ms 80 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Throttle sensor opening angle at full close point learning Threshold Value t 10.127 and d 19.872 t 1.683
Throttle opening angle when the ignition switch is ON Throttle minimum stop position
GD(H4DOTC)-213

GENERAL DESCRIPTION
EC:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-214

GENERAL DESCRIPTION
GD(H4DOTC)-215

GENERAL DESCRIPTION
ED:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-216

GENERAL DESCRIPTION
GD(H4DOTC)-217

GENERAL DESCRIPTION
EE:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-218

GENERAL DESCRIPTION
GD(H4DOTC)-219

GENERAL DESCRIPTION
EF:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-220

GENERAL DESCRIPTION
GD(H4DOTC)-221

GENERAL DESCRIPTION
EG:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-222

GENERAL DESCRIPTION
Map
GD(H4DOTC)-223

GENERAL DESCRIPTION
EH:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H4DOTC)-224

GENERAL DESCRIPTION
Map
Throttle position sensor 1 opening angle () = d Sensor output difference () 0 d d < 0.6 1.465 0.6 d d < 1.2 1.597 1.2 d d < 2 1.663 2dd<4 2.455 4dd 3.116
GD(H4DOTC)-225

GENERAL DESCRIPTION
EI: DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve 2. Judge as NG when the ECM output level differs from the actual terminal level.

GD(H4DOTC)-226

GENERAL DESCRIPTION
EJ:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH
Detect open or short circuit of the purge control solenoid valve 2. Judge as NG when the ECM output level differs from the actual terminal level.

GD(H4DOTC)-227

GENERAL DESCRIPTION
EK:DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE
Detect the malfunction of secondary air pressure sensor output property. Judge as NG when the secondary air pressure sensor output is largely different from the intake manifold pressure at engine start.
Secondary Parameters Engine speed Vehicle speed After secondary air system stops Enable Conditions < 300 rpm < 1 km/h (0.6 MPH) t 2976 ms

Perform the diagnosis with ignition switch ON.
Malfunction Criteria |Secondary air pipe pressure Intake manifold pressure| |Intake manifold pressure at engine start Intake manifold pressure| Threshold Value t 26.7 kPa (200 mmHg, 7.9 inHg) < 1.3 kPa (9.99 mmHg, 0.4 inHg)
Malfunction Criteria |Secondary air pipe pressure Intake manifold pressure| Threshold Value < 26.7 kPa (200 mmHg, 7.9 inHg)
GD(H4DOTC)-228

GENERAL DESCRIPTION
EL:DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW
Judge as NG if out of specification.

Malfunction Criteria Ignition switch Output voltage Threshold Value ON < 0.568 V
Malfunction Criteria Ignition switch Output voltage Threshold Value ON t 0.568 V
GD(H4DOTC)-229

GENERAL DESCRIPTION
EM:DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH
Judge as NG if out of specification.

Malfunction Criteria Ignition switch Output voltage Threshold Value ON > 4.921 V
Malfunction Criteria Ignition switch Output voltage Threshold Value ON d 4.921 V
GD(H4DOTC)-230

GENERAL DESCRIPTION
EN:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK1)
EO:DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK1)
EP:DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK2)
EQ:DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK2)
GD(H4DOTC)-231

GENERAL DESCRIPTION
ER:DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON

Detect the secondary air pump malfunction (always ON). After the secondary air pump turns to OFF, judge as NG if the secondary air pipe pressure is higher than that before the secondary air pump operation.
Secondary Parameters Battery voltage Engine Enable Conditions t7V In operation

Malfunction Criteria Time since secondary air control completion Threshold Value t 3000 ms and d 8000 ms > 6.7 kPa (50 mmHg, 2 inHg)
Secondary air pipe pressure Secondary air pipe pressure before operation
Malfunction Criteria Time since secondary air control completion Threshold Value t 3000 ms and d 8000 ms d 6.7 kPa (50 mmHg, 2 inHg)
Secondary air pipe pressure Secondary air pipe pressure before operation
GD(H4DOTC)-232
General Description
A: SPECIFICATION
Fuel tank Capacity Install locations Type Shutoff discharge pressure Discharge rate Fuel filter 64 2 (16.9 US gal, 14.1 Imp gal) Under rear seat Impeller 550 850 kPa (5.61 8.67 kg/cm2, 79.8 123.3 psi) 155 2 (41 US gal, 34.1 Imp gal)/h or more [12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)] In-tank type
Fuel pump
FU(H6DO)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T4 (16) T3 (9) T4
T2
(18)
(17) T5 (5) (6) T4 (7) T4 (17) T3 (10) (8) T5 (15) T2
(3) T4 (1) (2) T2 (11)
(14) (13) (14)
(4) (2) T4
T1
T2 T2 T2
T2
(14) (13) (14) T2 (12) T1 FU-04042
FU(H6DO)-3
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) Intake manifold O-ring Manifold absolute pressure sensor Filter Fuel pipe protector RH Purge control solenoid valve Hose Hose Plug (10) (11) (12) (13) (14) (15) (16) (17) Nipple Fuel pipe protector LH Fuel pipe ASSY Hose Clamp EGR valve Gasket Gasket (18) EGR pipe
Tightening torque:Nm (kgf-m, ft-lb) T1: 1.25 (0.1, 0.9) T2: 6.4 (0.7, 4.7) T3: 17 (1.7, 12.5) T4: 19 (1.9, 14.0) T5: 25 (2.5, 18.4)
2. FUEL INJECTOR
T
(6)
(5) (4) (3) (2) (1) T
(5) (4) (3) (2) FU-02561
(1) (2) (3)
Fuel injector pipe LH Insulator Fuel injector
(4) (5) (6)
Injection rubber O-ring Fuel injector pipe RH
FU(H6DO)-4
General Description

T
(2)
(1)
FU-02109
(1)
O-ring
(2)
Throttle body
FU(H6DO)-5
General Description
T4
T4 (2) T1
T2 (4)
(3) T1
(6)
(1) T1
(5)
T3
(8)
(7)
T2
FU-02110
(1) (2) (3) (4) (5)
Crankshaft position sensor Knock sensor RH Knock sensor LH Camshaft position sensor RH Camshaft position sensor LH
(6) (7) (8)
Variable valve lift diagnosis oil pressure switch RH Variable valve lift diagnosis oil pressure switch LH Oil temperature sensor
FU(H6DO)-6
General Description
5. FUEL TANK
T1 (27)
(28) (16) (16) (14) (7) (16) (6) (9) (16) (8) (14) (16) (25) (24) (1) (16) (29) (10) (30) (11) (32) (16) (13) (17) T1 (15) (26)
(31) T4 (12)
(18) (2) (19) T4 T3 T3
(3) T4 (20)
(5) (20) T3 T3 (21)
(22)
(23)
(4)
T3
T2
T2
T3 FU-04000
FU(H6DO)-7
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Fuel tank Fuel tank band RH Fuel tank band LH Delivery tube Jet pump tube Fuel pump ASSY Fuel pump upper plate Fuel pump gasket Fuel level sensor Fuel sub level sensor Fuel sub level sensor upper plate Fuel sub level sensor gasket Fuel filler hose (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) Clamp Evaporation hose A Clip Fuel tank protector LH (Rear) Stopper RH Stopper LH Retainer Heat shield cover Fuel tank protector RH (Front) Fuel tank protector LH (Front) Evaporation hose B Connector Evaporation hose C (27) (28) (29) (30) (31) (32) Evaporation hose D Evaporation pipe Evaporation hose E Evaporation hose F Fuel sub level sensor filter Fuel sub level sensor protector
FU(H6DO)-8
General Description
6. FUEL LINE
T4
(5) (6) (7) (8) (4)
T3
(1)
T3
(10) (4) (11) (4) (12)
T1
(4) (9) (2)
T1 T4
(3)
(4)
(4)
(13) (14)
T4
(4) C
T4
(20) (19)
T4 T4
(15)
(16)
T4
(17) (29) (4) (28) (4) (27) (23) (4) (24) (4) (21) (4) (22) (18) C
(4)
(26)
(25)
T6 T2 (39) (40) (39) T4 (41)

B
T5
(42) T4
(38) (35) (36) (34) (33) (37) (32) (43)

B
(4) (39) (30)
(4)
(31)
FU-03217
FU(H6DO)-9
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Evaporation pipe protector Evaporation hose D Evaporation pipe B Clip Fuel filler cap Filler ring Shut valve Gasket Evaporation hose C Evaporation hose C Evaporation pipe A Drain hose connector Drain hose Connector A Canister protector Drain filter Drain valve (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) Canister Fuel filler pipe Fuel tank pressure sensor Canister hose B Connector B Pressure control solenoid valve Canister hose A Connector B Connector A Evaporation hose E Evaporation tube Retainer Purge pipe Purge hose C Fuel hose Connector Fuel pipe ASSY (35) (36) (37) (38) (39) (40) (41) (42) (43) Fuel delivery hose A Fuel delivery hose B Clamp Quick connector check cover Clip Fuel damper Fuel damper holder Fuel damper bracket Evaporation hose A
Tightening torque:Nm (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 1.25 (0.1, 0.9) T3: 4.4 (0.4, 3.2) T4: 7.5 (0.8, 5.5) T5: 8 (0.8, 5.9) T6: 17.6 (1.8, 13.0)
FU(H6DO)-10
General Description
7. FUEL PUMP
(1)
(2) b (5) d (4) a b (2) C
(3)
(5)
(6)
(2) (8) d (10) C (7)
(9)
(12)
(13)
(11)
FU-04005
(1) (2) (3) (4) (5)
(6) (7) (8) (9)
(10) (11) (12) (13)
FU(H6DO)-11
General Description
C: CAUTION
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER 42099AE000 DESCRIPTION QUICK CONNECTOR RELEASE REMARKS Used for disconnecting quick connector of the engine compartment.
ST42099AE000
18471AA000
FUEL PIPE ADAPTER
ST18471AA000
1B022XU0
ST1B022XU0
FU(H6DO)-12
Throttle Body
2. Throttle Body
A: REMOVAL
IN-00203
3) Remove the air intake chamber. <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 4) Disconnect the connector from throttle body.
FU-02111
5) Disconnect the engine coolant hoses (A) from the throttle body. 6) Remove the bolts (B) which secure throttle body to intake manifold.
(A) (B)
(B)
(A)
FU-02112
B: INSTALLATION
FU(H6DO)-13
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Remove the collector cover. 2) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Disconnect the ground cable from battery.
9) Disconnect the PCV hose.
EC-02202
10) Disconnect the brake booster hose.
IN-00203
5) Remove the air cleaner case and air intake chamber. <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.> <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 6) Disconnect the connector (A) from the throttle body. 7) Disconnect the engine harness connector (B).
FU-03219
11) Disconnect the fuel hoses from the fuel pipe. (1) Disconnect the connector of fuel pipe by pushing the ST in the direction of arrow. ST 42099AE000 QUICK CONNECTOR RELEASE (2) Remove the clip and disconnect the evaporation hose from the pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
(A)
(B)
FU-02845
8) Disconnect the engine coolant hoses from the throttle body.

ST
FU-02866
FU-02114
FU(H6DO)-14
Intake Manifold
12) Remove the EGR pipe from EGR valve. NOTE: Be careful not to drop the gasket.
18) Remove the bolts which hold the fuel injector pipe RH to the cylinder head.
FU-02120 FU-00547
13) Remove the fuel pipe protector LH.
19) Remove the bolts which hold the intake manifold to the cylinder head. LH side
FU-02117
14) Remove the engine harness from the fuel injector pipe LH. 15) Remove the bolts which hold fuel injector pipe LH to cylinder head.
FU-02121
RH side
FU-02122

FU-02118
16) Remove the fuel pipe protector RH.
FU-02119
17) Remove the engine harness from the fuel injector pipe RH.
FU(H6DO)-15
Intake Manifold
B: INSTALLATION
1) Install the intake manifold onto cylinder heads. NOTE: Use new O-rings. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) RH side
4) Install the fuel pipe protector RH. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02119
5) Install the bolts which hold fuel injector pipe LH to cylinder head.
FU-02122
NOTE: Use new O-rings. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
LH side
FU-02121
2) Install the bolts which hold fuel injector pipe RH to cylinder head. NOTE: Use new O-rings. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02118
6) Install the engine harness to fuel injector pipe LH. 7) Install the fuel pipe protector LH. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02120
FU-02117
3) Install the engine harness to fuel injector pipe RH.
FU(H6DO)-16
Intake Manifold
8) Install the EGR pipe to EGR valve. NOTE: Use a new gasket. Tightening torque 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
12) Connect the engine coolant hoses to throttle body.
FU-02114
13) Connect the connector (A) to throttle body. 14) Connect the engine harness connector (B).
FU-00547
9) Connect the fuel hoses to fuel pipe.
(A)
(B)
FU-02845
FU-03218
10) Connect the brake booster hose.
15) Install the air cleaner case and air intake chamber. <Ref. to IN(H6DO)-6, INSTALLATION, Air Cleaner Case.> <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.> 16) Install the fuse of fuel pump to the main fuse box. 17) Connect the ground cable to battery.
FU-03219
11) Connect the PCV hose.

IN-00203
EC-02202
FU(H6DO)-17
Intake Manifold
C: DISASSEMBLY
1) Remove the engine harness from intake manifold. 2) Remove the throttle body. <Ref. to FU(H6DO)13, REMOVAL, Throttle Body.> 3) Remove the EGR valve. <Ref. to FU(H6DO)-27, REMOVAL, EGR Valve.> 4) Remove the manifold absolute pressure sensor. <Ref. to FU(H6DO)-25, REMOVAL, Manifold Absolute Pressure Sensor.> 5) Remove the purge control solenoid valve. <Ref. to EC(H6DO)-8, REMOVAL, Purge Control Solenoid Valve.> 6) Loosen the clamp which holds fuel injector pipe to the fuel hose, and then disconnect the pipe from fuel hose.
D: ASSEMBLY
NOTE: When assembling the nipple, apply liquid gasket. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 17 Nm (1.7 kgf-m, 12.5 ft-lb) 1) Tighten the bolts which install fuel pipes on intake manifold. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-02125
FU-02124
7) Remove the bolts which install fuel pipes on intake manifold.
FU-02126
2) Connect the fuel injector pipe to fuel hose, and tighten the clamp screw.
FU-02125
FU-02126
FU-02124
3) Install the purge control solenoid valve. <Ref. to EC(H6DO)-8, INSTALLATION, Purge Control Solenoid Valve.>
FU(H6DO)-18
Intake Manifold
4) Install the manifold absolute pressure sensor. <Ref. to FU(H6DO)-25, INSTALLATION, Manifold Absolute Pressure Sensor.> 5) Install the EGR valve. <Ref. to FU(H6DO)-27, INSTALLATION, EGR Valve.> 6) Install the throttle body to the intake manifold. <Ref. to FU(H6DO)-13, INSTALLATION, Throttle Body.> 7) Install the engine harness to the intake manifold.
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not damaged and the connections are tightened firmly.
FU(H6DO)-19


A: REMOVAL
IN-00203
3) Drain engine coolant. <Ref. to CO(H6DO)-10, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 4) Disconnect the connectors from the engine coolant temperature sensor.
FU-00572
B: INSTALLATION
FU-00572
FU(H6DO)-20


A: REMOVAL
B: INSTALLATION
IN-00203
FU-02128
3) Remove the air intake chamber. <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 4) Remove the service hole cover.
FU-02127
5) Remove the crankshaft position sensor.
FU-02128
6) Disconnect the connector from crankshaft position sensor.
FU(H6DO)-21


A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Camshaft position sensor 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) Fuel pipe protector 19 Nm (1.9 kgf-m, 14.0 ft-lb)
IN-00203
3) Remove the generator harness from the fuel pipe protector LH. 4) Remove the fuel pipe protector LH.
FU-02117
5) Disconnect the connector from camshaft position sensor LH.
FU-02129
6) Remove the camshaft position sensor LH.
FU-02130
7) Remove the camshaft position sensor RH in the same procedure as LH.
FU(H6DO)-22
Knock Sensor
7. Knock Sensor
A: REMOVAL
B: INSTALLATION
1) Install the knock sensor to cylinder block. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) NOTE: For the knock sensor installation angle, refer to the figure below.
30 10 45
IN-00203
3) Remove the intake manifold. <Ref. to FU(H6DO)-14, REMOVAL, Intake Manifold.> 4) Disconnect the knock sensor connector. 5) Remove the knock sensor from the cylinder block.
(A)
FU-00578
(A) Front side of vehicle
2) Connect the knock sensor connector. 3) Install the intake manifold. <Ref. to FU(H6DO)16, INSTALLATION, Intake Manifold.> 4) Connect the ground cable to battery.
FU-00577
IN-00203
FU(H6DO)-23


A: SPECIFICATION
Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to Throttle Body for removal and installation procedure. <Ref. to FU(H6DO)-13, REMOVAL, Throttle Body.> <Ref. to FU(H6DO)-13, INSTALLATION, Throttle Body.>
FU(H6DO)-24

9. Manifold Absolute Pressure Sensor

A: REMOVAL
IN-00203
3) Disconnect the connector from the manifold absolute pressure sensor (A), and remove the filter assembly (B) from the intake manifold.
(A)
(B) FU-02131
4) Remove the manifold absolute pressure sensor from intake manifold.
B: INSTALLATION
FU(H6DO)-25

10.Mass Air Flow and Intake Air Temperature Sensor

A: REMOVAL
IN-00203
2) Disconnect the connectors from the mass air flow and intake air temperature sensor.
IN-02009
3) Remove the mass air flow and intake air temperature sensor.
FU-03236
B: INSTALLATION
FU(H6DO)-26
EGR Valve
11.EGR Valve
A: REMOVAL
IN-00203
3) Remove the air intake chamber. <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 4) Remove the starter. <Ref. to SC(H4SO)-6, REMOVAL, Starter.> 5) Remove the EGR pipe from EGR valve and cylinder head. 6) Remove the EGR valve from intake manifold.
FU-02133
7) Disconnect the connector from the EGR valve.
B: INSTALLATION
Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: EGR valve 19 Nm (1.9 kgf-m, 14.0 ft-lb) EGR pipe 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
FU-02133
FU(H6DO)-27
Fuel Injector
12.Fuel Injector
A: REMOVAL
1. RH SIDE
1) Remove the collector cover. 2) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Disconnect the ground cable from battery.
9) Remove the bolt which holds fuel injector pipe onto cylinder head.
FU-02120
2. LH SIDE
1) Remove the collector cover. 2) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Remove the battery. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 5) Remove the generator harness from the fuel pipe protector LH. 6) Remove the fuel pipe protector LH.
IN-00203
5) Remove the air cleaner case. <Ref. IN(H6DO)-5, REMOVAL, Air Cleaner Case.> 6) Remove the fuel pipe protector RH.
to
FU-02119
FU-02117
FU-02134
8) Remove the engine harness from the fuel injector pipe RH.
FU-02135
8) Remove the engine harness from the fuel injector pipe LH.
FU(H6DO)-28
Fuel Injector
9) Remove the bolt which holds fuel injector pipe onto cylinder head.
2. LH SIDE
FU-02118
B: INSTALLATION
1. RH SIDE
Install in the reverse order of removal. NOTE: Use new O-rings. Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb) Tightening torque: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02118
FU-02117
FU-02120
FU-02119
FU(H6DO)-29
Variable Valve Lift Diagnosis Oil Pressure Switch

13.Variable Valve Lift Diagnosis Oil Pressure Switch

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. NOTE: Apply liquid gasket to the variable valve lift diagnosis oil pressure switch threads. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 17 Nm (1.7 kgf-m, 12.5 ft-lb)
IN-00203
3) Remove the air intake chamber. <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 4) Disconnect the connector from the variable valve lift diagnosis oil pressure switch. 5) Remove the variable valve lift diagnosis oil pressure switch. LH side
FU-02136
RH side
FU-02137
FU(H6DO)-30
Oil Temperature Sensor

14.Oil Temperature Sensor

A: REMOVAL
IN-00203
3) Remove the air intake chamber. <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 4) Disconnect the connector from the oil temperature sensor.
FU-02138
5) Remove the oil temperature sensor.
B: INSTALLATION
FU(H6DO)-31


A: REMOVAL
6) Remove the front oxygen (A/F) sensor. CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe. LH side
IN-00203
3) Lift up the vehicle. 4) Disconnect the connector of front oxygen (A/F) sensor. LH side
FU-02141
RH side
FU-02142 FU-02139
RH side
FU-02140
5) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more.
FU(H6DO)-32

B: INSTALLATION
CAUTION: If lubricant is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protector of front oxygen (A/F) sensor. Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the front oxygen (A/F) sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.5 ft-lb) LH side
3) Connect the connector of front oxygen (A/F) sensor. LH side
FU-02139
RH side
FU-02140
FU-02141
RH side
IN-00203
FU-02142
FU(H6DO)-33
Rear Oxygen Sensor


A: REMOVAL
7) Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe. LH side
IN-00203
3) Lift up the vehicle. 4) Disconnect the connector from rear oxygen sensor. LH side
FU-02145
RH side
FU-02146 FU-02143
RH side
FU-02144
5) Remove the clip holding the harness. 6) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more.
FU(H6DO)-34
Rear Oxygen Sensor

B: INSTALLATION
CAUTION: If lubricant is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protector of rear oxygen sensor. Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the rear oxygen sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.5 ft-lb) LH side
4) Connect the connector to rear oxygen sensor. LH side
FU-02143
RH side
FU-02144
FU-02145
RH side
IN-00203
FU-02146
3) Hold the harness with clip.
FU(H6DO)-35
SI-DRIVE (SUBARU Intelligent Drive) Selector

17.SI-DRIVE (SUBARU Intelligent Drive) Selector

A: REMOVAL
B: INSTALLATION
C: INSPECTION
Measure the resistance between SI-DRIVE selector terminals.
5 4 3 2 1
IN-00203
2) Remove the console box. <Ref. to EI-52, REMOVAL, Glove Box.> 3) Disconnect the SI-DRIVE selector connector.
FU-03123
Switch position Terminal No. Sport (when turning the SIDRIVE selector to the left) Intelligent (when pushing the SI2 and 3 DRIVE selector) Sport Sharp (when turning the SIDRIVE selector to the right)
Standard value Less than 10 :
0.8 1.2 k:
2.14 3.2 k:
FU-04006
4) Remove the screws which secure the SI-DRIVE selector to the console box.
FU-04007
5) Disconnect the connector from SI-DRIVE selector cover, and remove the SI-DRIVE selector.
FU-04008
FU(H6DO)-36
SI-DRIVE (SUBARU Intelligent Drive) S# Switch

18.SI-DRIVE (SUBARU Intelligent Drive) S# Switch

A: REMOVAL
C: INSPECTION
Measure the resistance between SI-DRIVE S# switch terminals.
4 3 2 1
FU-03121
IN-00203
2) Remove the airbag module. <Ref. to AB-14, REMOVAL, Drivers Airbag Module.> WARNING: Always refer to Airbag System before performing service on the airbag modules. <Ref. to AB-4, CAUTION, General Description.> 3) Remove the screws which secure the SI-DRIVE S# switch to the steering wheel, and remove the SIDRIVE S# switch.
Switch position ON (When the SI-DRIVE S# switch is pressed) OFF
Standard value Less than 10 : 1 M: or more
FU-03122
4) Disconnect the connectors from the SI-DRIVE S# switch.
B: INSTALLATION
FU(H6DO)-37


A: REMOVAL
B: INSTALLATION
IN-00203
FU-02090
5) Remove the nuts and bolts which hold the ECM to the bracket. 6) Remove the clip (A) from bracket.
(A)
FU-02488
FU(H6DO)-38
Main Relay
20.Main Relay
A: REMOVAL
IN-00203
(A)
FU-02092
FU-02406
B: INSTALLATION
FU(H6DO)-39
Fuel Pump Relay

21.Fuel Pump Relay

A: REMOVAL
IN-00203
(A)
FU-02092
FU-02407
B: INSTALLATION
FU(H6DO)-40


A: REMOVAL
IN-00203
(A)
FU-02092
FU-02408
B: INSTALLATION
FU(H6DO)-41
Fuel Pump Control Unit

23.Fuel Pump Control Unit

A: REMOVAL
5) Disconnect the connector from fuel pump control unit.
B: INSTALLATION
IN-00203
2) Remove the rear quarter trim of the left side. (Wagon model) <Ref. to EI-63, REMOVAL, Rear Quarter Trim.> 3) Peel the trunk side trim of the left side. (Sedan model) 4) Remove the fuel pump control unit. Wagon model
FU-03220
Sedan model
FU-03231
FU(H6DO)-42
Fuel
24.Fuel
A: PROCEDURE

WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. NOTE: If the fuel pump cannot be actuated, refer to DRAINING FUEL (THROUGH THE FUEL FILLER HOSE). <Ref. to FU(H6DO)-44, DRAINING FUEL (THROUGH THE FUEL FILLER HOSE), PROCEDURE, Fuel.> Be careful not to let the battery run-out. 1) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
FU-01122
2) Start the engine and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn the ignition switch to OFF.
ST
FU-02866
3) Connect ST to the fuel delivery hose. ST 18471AA000 FUEL PIPE ADAPTER 4) Connect the gasoline proof hose to ST and put the end of the hose in the container. 5) Drive the fuel pump and drain the fuel using Subaru Select Monitor. <Ref. to EN(H6DO)(diag)-54, FUEL PUMP CONTROL (ON/OFF OPERATION), OPERATION, System Operation Check Mode.> CAUTION: Be careful not to spill fuel.
FU(H6DO)-43
Fuel

WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. Fuel may remain in the fuel filler pipe. Draining the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (10 or less) before the operation. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the rear exhaust pipe and muffler. <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 4) Open the fuel filler lid, and remove the fuel filler cap. 5) Drain the fuel from the fuel filler pipe through the filler opening using the gasoline proof pump and the gasoline proof hose (10 or less). 6) Disconnect the fuel filler hose (A) from the fuel filler pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
(B)
(A) FU-02394
FU(H6DO)-44
Fuel Tank
25.Fuel Tank
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 4) Disconnect the ground cable from battery.
8) Remove the connector (A) and clip (B).

(B) (A)
FU-03222
(A)
(A)
(B) IN-00203
FU-03223
5) Remove the rear seat. 6) Remove the service hole cover of fuel pump.
10) Disconnect connector (A) from fuel sub level sensor. 11) Disconnect the quick connector on the fuel delivery hose (B). <Ref. to FU(H6DO)-65, REMOVAL, Fuel Delivery and Evaporation Lines.>
(A)
FU-02387

(B)
FU-02853
12) Remove the trunk room trim. (Sedan model) <Ref. to EI-70, REMOVAL, Trunk Room Trim.> 13) Remove the rear quarter trim. (Wagon model) <Ref. to EI-63, WAGON MODEL, REMOVAL, Rear Quarter Trim.>
FU-03221
FU(H6DO)-45
Fuel Tank
14) Remove the pipe protector.
FU-02390
20) Remove the parking brake cable from parking brake assembly. <Ref. to PB-6, REMOVAL, Parking Brake Assembly (Rear Disc Brake).> 21) Lift up the vehicle. 22) Remove the rear exhaust pipe. <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> 23) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 24) Remove the heat shield cover and fuel tank protector. 25) Disconnect the connector from the rear ABS wheel speed sensor.
15) Remove the grommet and disconnect the quick connector of the evaporation pipe. <Ref. to FU(H6DO)-65, REMOVAL, Fuel Delivery and Evaporation Lines.>
FU-02894
FU-02391
16) Remove the rear wheels. 17) Lift up the vehicle. 18) Remove the bolts which secure the rear brake hose mounting bracket.
FU-02895
FU-01128
FU-02896
FU-00462
FU(H6DO)-46
Fuel Tank
27) Remove the rear suspension assembly. CAUTION: A helper is required to perform this work. (1) Support the rear suspension assembly with the transmission jack. (2) Remove the bolts which hold the rear shock absorber to the rear suspension arm.
FU-02393
FU-01132
(A)
(B)
FU-02394
FU-01133
FU-02891
FU-03293
FU-02392
FU(H6DO)-47
Fuel Tank
B: INSTALLATION
FU-02393
FU-03293
2) Securely insert the fuel filler hose (A) and evaporation hose (B) to the specified position, then tighten the clip or clamp.
(B)
FU-02392
(A) FU-02394
(1)
(2)
(3)
L/2 L
FU-00104
(1) Hose (2) Clip or clamp (3) Pipe
FU(H6DO)-48
Fuel Tank
6) Install the rear suspension assembly. CAUTION: A helper is required to perform this work. (1) Support the rear suspension assembly with a transmission jack. (2) Support the rear suspension assembly, and tighten the bolts which secure the rear suspension assembly to the body. Tightening torque: T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb) T2: 175 Nm (17.8 kgf-m, 129.1 ft-lb)
T1 T1
FU-02895 T1
T1
FU-01150
FU-02896
T2
T2
FU-02892
FU-02894
9) Install the heat shield cover. Tightening torque: 17.5 Nm (1.8 kgf-m, 12.9 ft-lb) 10) Install the fuel tank protector. Tightening torque: Nut: 9 Nm (0.9 kgf-m, 6.6 ft-lb) Bolt: 17.5 Nm (1.8 kgf-m, 12.9 ft-lb) 11) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 12) Install the rear exhaust pipe. <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> 13) Lower the vehicle.
FU-01132
FU(H6DO)-49
Fuel Tank
20) Install the trunk room trim. (Sedan model) <Ref. to EI-71, INSTALLATION, Trunk Room Trim.> 21) Install the rear quarter trim. (Wagon model) <Ref. to EI-64, INSTALLATION, Rear Quarter Trim.> 22) Connect connector (A) to the fuel sub level sensor. 23) Connect the quick connector of the fuel delivery hose (B). <Ref. to FU(H6DO)-66, INSTALLATION, Fuel Delivery and Evaporation Lines.>
(A)
(B)
FU-01128
FU-02853
17) Install the rear wheels. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 18) Connect the quick connector of the evaporation pipe. <Ref. to FU(H6DO)-66, INSTALLATION, Fuel Delivery and Evaporation Lines.>
(A)
(A)
(B)
FU-03223

FU-02391
25) Connect connector (A) and install clip (B).

(B) (A)
T2 FU-03222 T1
FU-02868
FU(H6DO)-50
Fuel Tank
FU-03221
FU-02387
28) Install the rear seat. 29) Install the fuse of fuel pump to the main fuse box. 30) Connect the ground cable to battery.
IN-00203
C: INSPECTION
1) Check that the fuel tank does not have holes, cracks or is damaged in any way. 2) Make sure that the fuel pipe and fuel hose are not cracked and that the connections are tight.
FU(H6DO)-51
Fuel Filler Pipe

26.Fuel Filler Pipe

A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 4) Disconnect the ground cable from battery.
FU-02395
(B)
(A) FU-02396 IN-00203
5) Open the fuel filler lid, and remove the filler cap. 6) Remove the screws which secure gasket.
(B)
FU-02397
FU-00095
FU(H6DO)-52
Fuel Filler Pipe

B: INSTALLATION
1) Open the fuel filler lid. 2) Set the fuel saucer (A) with rubber gasket (C), and insert the fuel filler pipe into hole from the inner side of apron. 3) Align the holes in fuel filler pipe neck and set the cup (B), and tighten the screws. NOTE: If the edges of rubber gasket are folded toward inside, straighten it with a flat tip screwdriver.
(A) (1)
(2)
(3)
L/2 L
FU-00104
(1) Hose (2) Clip or clamp (3) Pipe
(B) (C)
FU-00103
4) Securely insert the fuel filler hose (A) and evaporation hose (B) into the specified position, then tighten the clamp or clip as shown in the figure. Tightening torque: 2.5 Nm (0.3 kgf-m, 1.8 ft-lb)
FU-02395
(B)
(A) FU-02396
(B)
FU-02397
IN-00203
FU(H6DO)-53
Fuel Filler Pipe

C: INSPECTION
1) Check that the fuel tank does not have holes, cracks or is damaged in any way. 2) Make sure that the fuel hose is not cracked and that the connections are tight.
E: ASSEMBLY
1) Install the shut valve to the fuel filler pipe. <Ref. to EC(H4SO)-15, INSTALLATION, Shut Valve.> 2) Tighten the nuts which secure the evaporation pipe assembly to the fuel filler pipe. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
D: DISASSEMBLY
FU-02399 FU-02398
FU-02400

FU-02399
FU-02398
FU-02400
3) Remove the shut valve from the fuel filler pipe. <Ref. to EC(H4SO)-15, REMOVAL, Shut Valve.>
FU(H6DO)-54
Fuel Pump
27.Fuel Pump
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: Fuel pump assembly consists of fuel pump, fuel filter and fuel level sensor. 1) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 3) Disconnect the ground cable from battery.
FU-03221
7) Disconnect the quick connector on the fuel delivery hose and jet pump hose. <Ref. to FU(H6DO)65, REMOVAL, Fuel Delivery and Evaporation Lines.>
(B)
(A)
FU-02670
(A) Fuel delivery hose (B) Jet pump hose
IN-00203
8) Remove the nuts which install fuel pump assembly onto fuel tank. 9) Remove the fuel pump assembly from the fuel tank.
4) Remove the rear seat. 5) Remove the service hole cover.
FU-02387
FU(H6DO)-55
Fuel Pump
B: INSTALLATION
Install in the reverse order of removal while being careful of the following. Make sure the sealing portion is free from fuel or foreign matter before installation. When assembling, point the protrusion of the gasket (A) towards the front of the vehicle. Insert the protrusion (B) of the gasket into the upper plate. (3 places) Align the protrusion (C) of the fuel pump assembly to the cut out in the upper plate. Tighten the nuts to the specified torque in the order as shown in the figure. NOTE: Use new gasket and retainer. Tightening torque: 4.4 Nm (0.4 kgf-m, 3.2 ft-lb)
1 4 (B) 6 5 (C) 8 (B)
7 (B) 2 (A)
3
FU-02835
C: INSPECTION
Connect the lead harness to the connector terminal of fuel pump, and apply the battery power supply to check whether the pump operates. CAUTION: Wipe off fuel completely. Keep the battery as far apart from fuel pump as possible. Be sure to perform the ON/OFF operation on the battery side. Do not run the fuel pump for a long time under non-load condition.
2 1 4 3 6 5
FU-01330
FU(H6DO)-56
Fuel Level Sensor


A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: The fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. <Ref. to FU(H6DO)-55, REMOVAL, Fuel Pump.> 2) Disconnect the connector from fuel pump bracket. 3) Remove the fuel temperature sensor. 4) Remove the fuel level sensor.
(A) (C)
(B) FU-04001
B: INSTALLATION
FU(H6DO)-57


A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. 1) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Drain fuel. <Ref. to FU(H6DO)-43, DRAINING FUEL (WITH SUBARU SELECT MONITOR), PROCEDURE, Fuel.> 3) Disconnect the ground cable from battery.
FU-03010
7) Disconnect the quick connector on the fuel delivery hose and jet pump hose. <Ref. to FU(H6DO)65, REMOVAL, Fuel Delivery and Evaporation Lines.> 8) Remove the nuts and bolts which install fuel sub level sensor on fuel tank.
(A)
(B) FU-02673
IN-00203
(A) Jet pump hose (B) Fuel delivery hose
(A)
(A)
(B)
FU-03223
FU(H6DO)-58

B: INSTALLATION
Install in the reverse order of removal while being careful of the following. Make sure the sealing portion is free from fuel or foreign matter before installation. Align protrusion (A) of the gasket to the position shown in the following figure. Align the protrusion (B) of fuel sub level sensor with the cutout on the upper plate of fuel sub level sensor. Tighten the nuts and bolts to the specified torque in the order as shown in the figure. NOTE: Use a new gasket and retainer. Tightening torque: 4.4 Nm (0.4 kgf-m, 3.2 ft-lb)
3 1 5
6 2 4 (A)
FU-02836
(B)
FU-02674
FU(H6DO)-59
Fuel Filter
30.Fuel Filter
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. Be careful not to drop or apply any impact to the fuel pump during work. This may deteriorate its performance. NOTE: The fuel filter is built in fuel pump assembly. 1) Remove the fuel pump assembly. <Ref. to FU(H6DO)-55, REMOVAL, Fuel Pump.> 2) Remove the fuel level sensor and fuel temperature sensor. <Ref. to FU(H6DO)-57, REMOVAL, Fuel Level Sensor.> 3) Disconnect the pump assembly connector from the sub tank bracket assembly.
FU-03851
(A)
FU-03852

FU-03983
4) Cut off the tab holders connecting the sub tank bracket assembly and the sub tank in four locations, and separate the two. CAUTION: Be careful not to damage the sub tank. NOTE: If the O-ring is remaining on the subtank, remove.
FU-03986
FU-03984
FU(H6DO)-60
Fuel Filter
8) Lift the two tab holders connecting the pump assembly to the fuel filter using a flat tip screwdriver [with a shaft diameter of approx. 3 mm (0.12 in)], etc., and separate the fuel filter and pump assembly. CAUTION: To prevent damaging the tabs of the pump assembly, wrap the tip of flat tip screwdriver (A), etc. with tape (B).
(B) (A)
B: INSTALLATION
1) Assemble o-ring (A) and spacer (B) to the fuel pump, and attach the pump assembly to the fuel filter. NOTE: Use new O-rings [8 mm (0.31 in) inner diameter]. Use a new spacer. Apply gasoline to the o-ring. Insert the pump assembly until a pop is heard.
(B) FU-03929
Be careful not to drop or apply any impact to the pump assembly. NOTE: If the spacer and O-ring is remaining on the pump assembly, remove these.
(A)
FU-03859
FU-03927
FU-03986
FU(H6DO)-61
Fuel Filter
(A) (A) FU-03851
6) Attach the O-ring (A) to the fuel filter assembly, and attach the subtank to the sub tank bracket assembly.
FU-03985
(A)
NOTE: Use new O-rings [8 mm (0.31 in) inner diameter]. Apply gasoline to the o-ring. Insert the pump assembly until a pop is heard.
FU-03861 (A)
FU-03987
FU(H6DO)-62
Fuel Filter
FU-03863
FU-03983
9) Install the fuel level sensor and fuel temperature sensor. <Ref. to FU(H6DO)-57, INSTALLATION, Fuel Level Sensor.> 10) Install the fuel pump assembly. <Ref. to FU(H6DO)-56, INSTALLATION, Fuel Pump.>
FU(H6DO)-63
Fuel Damper
31.Fuel Damper
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. 1) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 2) Remove the fuel damper from the fuel delivery line.
FU-03008
B: INSTALLATION
FU(H6DO)-64

32.Fuel Delivery and Evaporation Lines

A: REMOVAL
FU-03224
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. 1) Set the vehicle on a lift. 2) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Remove the floor mat. <Ref. to EI-72, REMOVAL, Floor Mat.> 5) In the engine compartment, disconnect the fuel delivery hoses and evaporation hose. (1) Disconnect the quick connector of the fuel delivery line by pushing the ST in the direction of the arrow. ST 42099AE000 QUICK CONNECTOR RELEASE
(2) Remove the clip and disconnect the evaporation hose from the pipe. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
ST
FU-02866
FU(H6DO)-65

6) Lift up the vehicle. 7) Remove the canister. <Ref. to EC(H6DO)-6, REMOVAL, Canister.> 8) Remove the fuel tank. <Ref. to FU(H6DO)-45, REMOVAL, Fuel Tank.> 9) Remove the fuel pipe assembly. 10) Disconnect the quick connector, and then disconnect the fuel delivery hose and jet pump hose. (1) Clean the pipe and connector, if they are covered with dust. (2) To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag etc.
B: INSTALLATION

(A)
(B)
FU-01333
FU-00125
1) Set the new retainer (B) to connector (A). 2) Push the pipe into the connector completely.
(A) (B)
(B) (A) (C)
(C)
FU-00124
FU-00126
FU(H6DO)-66


(A) (1) (2) (3)
(B)
(C)
FU-00127
L/2 L FU-00129
2. CONNECTING THE FUEL DELIVERY HOSE

Connect the fuel delivery hose to the pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When the amount to be inserted is specified. Type B: When the amount to be inserted is not specified. L1: 2.5r1.5 mm (0.098r0.059 in) L2: 22.5r2.5 mm (0.886r0.098 in) CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel.
(3) (1) L1 L2 (2) L1 FU-03390 (4) (5)
C: INSPECTION
(1) (2) (3) (4) (5)
FU(H6DO)-67


A: INSPECTION
Trouble and possible cause 1. Insufficient fuel supply to injector 1) Fuel pump does not operate. Defective terminal contact Trouble in electromagnetic or electronic circuit parts Decline of fuel pump function Clogged fuel filter Clogged or bent fuel pipe or hose Air is mixed in the fuel system. Clogged or bent air breather tube or pipe Damaged diaphragm of pressure regulator Corrective action
2) 3) 4) 5) 6) 7)
Inspect contact, especially ground, and tighten it securely. Replace the faulty parts. Replace the fuel pump. Replace the fuel filter. Clean or replace the fuel tank if necessary. Clean, correct or replace fuel pipe or hose. Inspect or retighten each connection part. Clean, correct or replace the air breather tube or pipe. Replace. Retighten. Replace. Replace. Clean, correct or replace the air breather tube or air vent tube.
3. Gasoline smell inside of compartment Loose joints at air breather tube, air vent tube and fuel filler 1) pipe 2) Problem in tightening of the fuel saucer gasket air 3) Inoperative fuel pump modulator or circuit 4. Defective fuel meter indicator 1) Defective operation of fuel level sensor 2) Defective operation of fuel meter 5. Noise 1) Large operation noise or vibration of fuel pump
NOTE: When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. Fill the fuel tank fully to prevent this. In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop to 0C (32F) or less throughout the winter season, use a water removing agent in the fuel system to prevent freezing fuel system and accumulating water. When water is accumulated in fuel filter, fill the water removing agent in the fuel tank. Before using water removing agent, follow the cautions noted on the bottle.
FU(H6DO)-68
General Description
A: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
EC(H6DO)-2


A: REMOVAL
The front and rear catalytic converters are integrated into the front exhaust pipe; therefore, refer to Front Exhaust Pipe for the removal procedure. <Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.>
(A)
(B)
EC-02018
(A) Front catalytic converter (B) Rear catalytic converter
B: INSTALLATION
The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to Front Exhaust Pipe for installation procedure. <Ref. to EX(H6DO)-5, INSTALLATION, Front Exhaust Pipe.>
(A)
(B)
EC-02018
C: INSPECTION
EC(H6DO)-3


A: REMOVAL
The front and rear catalytic converters are integrated into the front exhaust pipe; therefore, refer to Front Exhaust Pipe for the removal procedure. <Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.>
(A)
(B)
EC-02018
B: INSTALLATION
The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to Front Exhaust Pipe for installation procedure. <Ref. to EX(H6DO)-5, INSTALLATION, Front Exhaust Pipe.>
(A)
(B)
EC-02018
C: INSPECTION
EC(H6DO)-4
EGR Valve
4. EGR Valve
A: REMOVAL
For removal procedures, refer to FU section. <Ref. to FU(H6DO)-27, REMOVAL, EGR Valve.>
B: INSTALLATION
For installation procedures, refer to FU section. <Ref. to FU(H6DO)-27, INSTALLATION, EGR Valve.>
EC(H6DO)-5
Canister
5. Canister
A: REMOVAL
IN-00203
(B)
EC-02080
(A)
(C) (A) EC-02079
EC(H6DO)-6
Canister
B: INSTALLATION
EC-02080
C: INSPECTION
EC(H6DO)-7


A: REMOVAL
B: INSTALLATION
IN-00203
EC-02019
3) Remove the air intake chamber. <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 4) Disconnect the connector and hoses of purge control solenoid valve, and then remove the purge control solenoid valve.
NOTE: Connect the evaporation hose as shown in the figure.
(B)
(A) EC-02020
EC-02019
(A) To fuel pipe (evaporation line) (B) To intake manifold
C: INSPECTION
EC(H6DO)-8
Fuel Level Sensor


A: REMOVAL
For removal procedure, refer to FU(H6DO) section. <Ref. to FU(H6DO)-57, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
For installation procedure, refer to FU(H6DO) section. <Ref. to FU(H6DO)-57, INSTALLATION, Fuel Level Sensor.>
EC(H6DO)-9


A: REMOVAL
The fuel temperature sensor is integrated into fuel level sensor as one unit; therefore, refer to Fuel Level Sensor for removal procedure. <Ref. to FU(H6DO)-57, REMOVAL, Fuel Level Sensor.>
(A)
EC-02408
B: INSTALLATION
The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to Fuel Level Sensor for installation procedure. <Ref. to FU(H6DO)-57, INSTALLATION, Fuel Level Sensor.>
(A)
EC-02408
EC(H6DO)-10


A: REMOVAL
For removal procedure, refer to FU(H6DO) section. <Ref. to FU(H6DO)-58, REMOVAL, Fuel Sub Level Sensor.>
B: INSTALLATION
For installation procedure, refer to FU(H6DO) section. <Ref. to FU(H6DO)-59, INSTALLATION, Fuel Sub Level Sensor.>
EC(H6DO)-11

10.Fuel Tank Pressure Sensor

A: REMOVAL
C: INSPECTION
IN-00203
3) Open the fuel filler lid and remove the fuel filler cap. 4) Lift up the vehicle. 5) Disconnect the connector from the fuel tank pressure sensor. 6) Disconnect the pressure hose from the fuel tank pressure sensor. 7) Remove the fuel tank pressure sensor along with the bracket.
EC-02084
B: INSTALLATION
EC-02084
EC(H6DO)-12


A: REMOVAL
C: INSPECTION
IN-00203
(A) (B)
(B) (C)
EC-02086
EC-02087
B: INSTALLATION
EC(H6DO)-13
Drain Filter
12.Drain Filter
A: SPECIFICATION
Canister is a non-disassembled part, so do not remove the drain filter from canister. Refer to Canister for removal and installation procedures. <Ref. to EC(H6DO)-6, REMOVAL, Canister.> <Ref. to EC(H6DO)-7, INSTALLATION, Canister.>
EC(H6DO)-14
Shut Valve
13.Shut Valve
A: REMOVAL
WARNING: Place NO OPEN FLAMES signs near the working area. CAUTION: Be careful not to spill fuel. 1) Remove the fuel filler pipe. <Ref. to FU(H6DO)52, REMOVAL, Fuel Filler Pipe.> 2) Disconnect the evaporation hose from the shut valve.
EC-02088
EC-02089
B: INSTALLATION
EC-02089
C: INSPECTION
EC(H6DO)-15
Drain Valve
14.Drain Valve
A: SPECIFICATION
Canister is a non-disassembled part, so do not remove the drain valve from canister. Refer to Canister for removal and installation procedures. <Ref. to EC(H6DO)-6, REMOVAL, Canister.> <Ref. to EC(H6DO)-7, INSTALLATION, Canister.>
EC(H6DO)-16
PCV Valve
15.PCV Valve
A: REMOVAL
1) Disconnect the PCV hose.
EC-02202
2) Remove the PCV valve from rocker cover.
EC-02203
B: INSTALLATION
Install in the reverse order of removal. NOTE: Apply liquid gasket to the bolt threads of PCV valve. Liquid gasket: THREE BOND 1141 (Part No. 004403006) or equivalent Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
EC(H6DO)-17
PCV Valve
EC(H6DO)-18
General Description
INTAKE (INDUCTION)
A: COMPONENT
T2 (14) (13) T3 (11) (10) T3 T2 (14) (13) (15)
(12)
T3 (16)
(9) (9) (8) (7) T4 (4) (17) T5 (18)
(3) T1 (2)
(6) (5) (1) IN-02212
IN(H6DO)-2
General Description
INTAKE (INDUCTION)
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Air intake duct Clip Resonator chamber Air cleaner case (front) Spacer Cushion Air cleaner element Air cleaner case (rear) Clip Clamp (11) (12) (13) (14) (15) (16) (17) (18) Intake boot Clamp Cushion Spacer Air intake chamber Clamp Cushion Mass air flow and intake air temperature sensor Tightening torque:Nm (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 6.5 (0.7, 4.8) T3: 3 (0.3, 2.2) T4: 7.5 (0.8, 5.5) T5: 1 (0.1, 0.7)
B: CAUTION
IN(H6DO)-3
Air Cleaner Element

INTAKE (INDUCTION)

A: REMOVAL
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Be sure to use SUBARU genuine air cleaner element depending on the engine type when replacing the air cleaner elements. Using other air cleaner element may affect the engine performance. NOTE: Check that there are no foreign objects in the air cleaner case. When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.
IN-00203
IN-00207 IN-02009
C: INSPECTION
Replace if excessively damaged or dirty.
3) Remove the clip (A) securing upper side of air cleaner case.
(A)
IN-02010
4) Pull the air cleaner case (rear) backward of the vehicle, and remove the air cleaner element. NOTE: Be careful of the power steering hose fixed to the bottom of the air cleaner case (rear).
IN(H6DO)-4
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case

A: REMOVAL
IN-00206
IN-00203
7) Remove the bolts (A) and nut (B) which secure the air cleaner case to body.
(B)
2) Remove the air intake duct. <Ref. to IN(H6DO)8, REMOVAL, Air Intake Duct.> 3) Disconnect the connector from mass air flow and intake air temperature sensor.
(A)
IN-02213
IN-02009
(B)
(A)
IN-02011
IN(H6DO)-5
Air Cleaner Case

INTAKE (INDUCTION)
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Bolt (A) 6 Nm (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
(B)
(A)
IN-02213
NOTE: When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.
IN-00207
Tightening torque: Clamp (A) 3 Nm (0.3 kgf-m, 2.2 ft-lb)
(B)
(A)
IN-02011
C: INSPECTION
IN(H6DO)-6
Air Intake Chamber

INTAKE (INDUCTION)
4. Air Intake Chamber

A: REMOVAL
1) Remove the collector cover. 2) Loosen the clamp (A) which connects air intake chamber to throttle body. 3) Loosen the clamp (B) which connects intake boot to air intake chamber. 4) Remove the bolt (C) which secures air intake chamber to the stay.
(A)
(B)
(C)
(C) IN-02095
5) Disconnect the blow-by hoses, then remove the air intake chamber.
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Clamp (A), (B) 3 Nm (0.3 kgf-m, 2.2 ft-lb) Bolt (C) 6.5 Nm (0.7 kgf-m, 4.8 ft-lb)
(A)
(B)
(C)
(C) IN-02095
C: INSPECTION
1) Check for cracks or loose connections. 2) Check that no foreign matter is mixed in air intake chamber.
IN(H6DO)-7
Air Intake Duct

INTAKE (INDUCTION)
5. Air Intake Duct

A: REMOVAL
IN-02013
B: INSTALLATION
C: INSPECTION
1) Check for cracks or loose connections. 2) Check that no foreign matter is mixed in air intake duct.
IN(H6DO)-8
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to Air Cleaner Case for removal procedure. <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to Air Cleaner Case for installation procedure. <Ref. to IN(H6DO)-6, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H6DO)-9
Resonator Chamber
INTAKE (INDUCTION)
IN(H6DO)-10
General Description
MECHANICAL
A: SPECIFICATION
Cylinder arrangement Valve system mechanism Bore Stroke Displacement Compression ratio Compression pressure (350 rpm and fully open throttle): Number of piston rings Engine Intake valve timing Max. retard Exhaust valve timing Valve clearance Idle rpm [P or N range] Ignition order Ignition timing mm (in) Intake Exhaust No load rpm A/C ON BTDC/rpm Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine Chain driven, double overhead camshaft, 4-valve/cylinder mm (in) 89.2 80 (3.512 3.150) cm3 (cu in) kPa (kgf/cm2, psi) 3,000 (183) 10.7 1,275 1,471 (13.0 15.0, 185 213) Pressure ring: 2, Oil ring: 1 BTDC 47 ABDC 23 ATDC 3 ABDC 73 BBDC 46 ATDC 6 0.20+0.04 -0.06 (0.0079+0.0016 -0.0024) 0.35r0.05 (0.0138r0.0020) 650r50 770r50 1o6o3o2o5o4 15r8/650
Min. advance
Open Close Open Close Open Close
ME(H6DO)-2
General Description
MECHANICAL
NOTE: OS: Oversize US: Undersize

Bending limit Side clearance mm (in) Standard Standard HIGH Standard Intake LOW1 Standard mm (in) LOW2 Standard Exhaust Standard HIGH Standard Intake LOW1 Standard mm (in) LOW2 Standard Exhaust Standard Front Standard mm (in) Except for front Standard mm (in) Standard Intake mm (in) Exhaust mm (in) Standard mm (in) mm (in) Intake Exhaust Standard Standard mm (in) mm (in) Standard Standard Intake Exhaust Standard Standard Intake Exhaust mm (in) mm (in) Intake Exhaust Squareness Standard height Warping limit (Mating surface with cylinder head) Cylinder block Cylinder inner diameter Cylindricality Out-of-roundness Piston clearance Cylinder inner diameter boring limit (diameter) Intake Exhaust mm (in) mm (in) Standard mm (in) Standard A B mm (in) Standard mm (in) Standard Inner Outer Inner Outer 0.020 (0.00079) 0.075 0.135 (0.0030 0.0053) 0.030 0.090 (0.0012 0.0035) 42.09 42.19 (1.6571 1.6610) 38.14 38.24 (1.5016 1.5055) 38.14 38.24 (1.5016 1.5055) 40.45 40.55 (1.5925 1.5965) 32.00 (1.2598) 31.84 (1.2535) 31.84 (1.2535) 32.00 (1.2598) 37.946 37.963 (1.4939 1.4946) 25.946 25.963 (1.0215 1.0222) 0.037 0.072 (0.0015 0.0028) 0.02 (0.0008) 32.994 33.016 (1.2990 1.2998) 124r0.05 (4.88r0.0020) 90 1.0 (0.039) 1.5 (0.059) 5.500 5.512 (0.2165 0.2170) 11.4 11.8 (0.449 0.465) 1.0 (0.039) 1.2 (0.047) 5.455 5.470 (0.2148 0.2154) 5.445 5.460 (0.2144 0.2150) 0.030 0.057 (0.0012 0.0022) 0.040 0.067 (0.0016 0.0026) 99.7 (3.925) 105.2 (4.142) 32.959 32.975 (1.2976 1.2982) 39.55 (1.5571) 41.18 (1.6213) 46.32 (1.8236) 2.5, 1.7 mm (0.067 in) or less 2.5, 1.8 mm (0.071 in) or less 2.5, 2.0 mm (0.079 in) or less 202 (7.95) 0.02 (0.0008) 89.205 89.215 (3.5120 3.5124) 89.195 89.205 (3.5116 3.5120) 0.030 (0.0012) 0.010 (0.0004) 0.010 0.010 (0.0004 0.0004) To 89.715 (3.5321)
Cam lobe height Camshaft Cam base circle diameter
Journal O.D.
Cylinder head
Oil clearance Warping limit (Mating surface with cylinder block) Inner diameter of valve lifter hole Standard height Seating angle Contacting width Inside diameter Protrusion above head Head edge thickness Stem outer diameter
Valve seat
mm (in)
Valve guide
mm (in)
Intake Exhaust mm (in)
Valve
Stem oil clearance Overall length Outer diameter of valve lifter Free length
mm (in)
Intake Exhaust mm (in)
Valve spring
mm (in) Standard mm (in)
ME(H6DO)-3
General Description
MECHANICAL
Standard Piston Outer diameter 0.25 (0.0098) OS 0.50 (0.0197) OS Inner diameter of piston pin hole mm (in) Outer diameter mm (in) Standard clearance between piston and piston pin mm (in) Top ring Ring closed gap mm (in) Second ring Oil ring Top ring Ring groove gap mm (in) Second ring Oil ring Thrust clearance Oil clearance Bearing of large end mm (in) A B 89.205 89.215 (3.5120 3.5124) 89.195 89.205 (3.5116 3.5120) 89.445 89.465 (3.5215 3.5222) 89.695 89.715 (3.5313 3.5321) 22.000 22.006 (0.8661 0.8664) 21.994 22.000 (0.8659 0.8661) 0.004 0.008 (0.0002 0.0003) 0.20 0.35 (0.0079 0.0138) 0.35 0.50 (0.0138 0.0197) 0.20 0.60 (0.0079 0.0236) 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028) 0.045 0.125 (0.0018 0.0049) 0.070 0.330 (0.0028 0.0130) 0.016 0.043 (0.0006 0.0017) 1.490 1.506 (0.0587 0.0593) 1.509 1.513 (0.0594 0.0596) 1.519 1.523 (0.0598 0.0600) 1.619 1.623 (0.0637 0.0639) 0 0.022 (0 0.0009) 0.005 (0.0002) 0.006 (0.0002) 51.984 52.000 (2.0466 2.0472) 51.954 51.970 (2.0454 2.0461) 51.934 51.950 (2.0446 2.0453) 51.734 51.750 (2.0368 2.0374) 63.992 64.008 (2.5194 2.5200) 63.962 63.978 (2.5182 2.5188) 63.942 63.958 (2.5174 2.5180) 63.742 63.758 (2.5095 2.5102) 63.992 64.008 (2.5194 2.5200) 63.962 63.978 (2.5182 2.5188) 63.942 63.958 (2.5174 2.5180) 63.742 63.758 (2.5095 2.5102) 0.030 0.115 (0.0012 0.0045) 0.010 0.030 (0.0004 0.0012) 1.992 2.005 (0.0784 0.0789) 2.011 2.014 (0.0792 0.0793) 2.021 2.024 (0.0796 0.0797) 2.121 2.124 (0.0835 0.0836) 1.996 2.009 (0.0786 0.0791) 2.015 2.018 (0.0793 0.0794) 2.025 2.028 (0.0797 0.0798) 2.125 2.128 (0.0837 0.0838)
Piston pin
Piston ring
Standard Standard Standard Standard Standard Standard Standard Standard Standard
Connecting rod
mm (in) Standard mm (in) Standard Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US mm (in) Standard
Bearing size (Thickness at center)
Clearance between piston pin and bushing Crank pin and crank journal
Crank pin outer diameter
Crankshaft Crank journal outer diameter
Out-of-roundness mm (in) Cylindricality mm (in) Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Standard #1, #3, 0.03 (0.0012) US #5, #7 0.05 (0.0020) US 0.25 (0.0098) US mm (in) Standard #2, #4, 0.03 (0.0012) US #6 0.05 (0.0020) US 0.25 (0.0098) US mm (in) Standard mm (in) Standard #1, #3, #5, #7 Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US
Thrust clearance Oil clearance
Main bearing
Bearing size (Thickness at center)
mm (in) #2, #4, #6
ME(H6DO)-4
General Description
MECHANICAL
B: COMPONENT
1. V-BELT
(5) (6)
(4) (3)
T2
(10) (2) T3
T3
(7)
(10)
T1 (9) T4
(8)
(1) ME-03100
(1) (2) (3) (4) (5)
V-belt Collector cover bracket Belt tension adjuster ASSY Power steering pump bracket Generator
(6) (7) (8) (9) (10)
Generator plate A/C compressor stay Idler pulley Idler pulley cover Cushion
ME(H6DO)-5
General Description
MECHANICAL
2. TIMING CHAIN COVER
T3
(8) T3
T2
T3 (7) (4) T2 T3 T3
T1 (1) (2) (5) (6)
(3)
T2 T2
T4
ME-03328
(1) (2) (3) (4)
Crank pulley cover O-ring Crank pulley Sealing washer
(5) (6) (7) (8)
Oil seal Front chain cover Rear chain cover Water pump gasket
Tightening torque:Nm (kgf-m, ft-lb) T1: <Ref. to ME(H6DO)-43, Crank Pulley.> T2: <Ref. to ME(H6DO)-44, Front Chain Cover.> T3: <Ref. to ME(H6DO)-53, Rear Chain Cover.> T4: 6.4 (0.7, 4.7)
ME(H6DO)-6
General Description
MECHANICAL
3. TIMING CHAIN
(4) (3) (9) (1) (8)
(2) T6 (5) (6)
T1
T4 (11) T2 (12) T4 (10) (13) (23) T3 (7) (24) (22) T1 T4 (23) (20) T4 (15) T1 (16) T4 (14) (18) (19) (17)
T5
T3 (21) ME-02380
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Crank sprocket Oil relief case Inner rotor Outer rotor Chain guide (center) Intake cam sprocket (RH) Exhaust cam sprocket (RH) Chain guide (RH: between cams) Timing chain (RH) Chain guide (RH) Chain tensioner lever (RH)
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Chain tensioner (RH) Chain tensioner lever (LH) Chain tensioner (LH) Water pump O-ring Chain guide (LH) Chain guide (LH: between cams) Timing chain (LH) Intake cam sprocket (LH) Exhaust cam sprocket (LH) Idler sprocket (lower)
(23) (24)
Idler sprocket collar Idler sprocket (upper)
Tightening torque:Nm (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 7.8 (0.8, 5.8) T3: <Ref. to ME(H6DO)-51, Cam Sprocket.> T4: 16 (1.6, 11.8) T5: 69 (7.0, 50.9) T6: <Ref. to LU(H6DO)-9, Oil Pump.>
ME(H6DO)-7
General Description
MECHANICAL

T2 T8 (37) (17) (7) T4 T2 T6 (8) T5 (10) (6) (5) (36) T4 T8 (17) (13) (18) T1 (20) (21) (16) T1 (19) T3 (12) T4 (11) (14) (15) (9) (38) (1) (38) T3 (4) T4 (2)
(3)
T4
(26) T6
(38)
(22) (23)
(28) (24) (25) (32) T2 (17) (37) T8 (30) (31) (36) (34) T8 T4 T7 T5
(27)
(38)
(29) (33)
(35) T2
(17)
ME-03351
ME(H6DO)-8
General Description
MECHANICAL
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Rocker cover (RH) Oil switching solenoid valve (RH) Oil switching solenoid valve holder (RH) Oil switching solenoid valve gasket (RH) Front chain cover Oil pipe (RH) Oil flow control solenoid valve (RH) Intake camshaft cap (Center RH) Intake camshaft cap (Rear RH) Exhaust camshaft cap (Rear RH) Exhaust camshaft cap (Center RH) Exhaust camshaft cap (Front RH) Front camshaft cap (RH) Intake camshaft (RH) Exhaust camshaft (RH) Cylinder head (RH) Gasket (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) Cylinder head gasket (RH) Oil switching solenoid valve (LH) Oil switching solenoid valve holder (LH) Oil switching solenoid valve gasket (LH) (35) (36) (37) (38) Rocker cover (LH) Union screw with filter (with protrusion) Union screw without filter (without protrusion) Rocker cover gasket
Cylinder head gasket (LH) Cylinder head (LH) Tightening torque:Nm (kgf-m, ft-lb) Intake camshaft (LH) T1: <Ref. to ME(H6DO)-59, Cylinder Head.> Exhaust camshaft (LH) Oil flow control solenoid valve (LH) T2: <Ref. to ME(H6DO)-55, Camshaft.> Intake camshaft cap (Rear LH) Intake camshaft cap (Center LH) T3: <Ref. to ME(H6DO)-80, Oil Switching Solenoid Valve.> Exhaust camshaft cap (Rear LH) Exhaust camshaft cap (Center LH) T4: 6.4 (0.7, 4.7) Exhaust camshaft cap (Front LH) T5: 9.75 (1.0, 7.2) Front camshaft cap (LH) T6: 16 (1.6, 11.8) Plug T7: 60 (6.1, 44.3) Oil pipe (LH) T8: 29 (3.0, 21.4)
ME(H6DO)-9
General Description
MECHANICAL
(1)
(3)
(4)
(5)
(6)
(7)
(8) (9) (10) (11)
(2)
(12) (4) (16) (13)
(14) (8) (9) (15)
ME-03102
(1) (2) (3) (4) (5) (6)
Exhaust valve Intake valve Intake valve guide Valve spring seat Intake valve stem seal Valve spring (Inner)
(7) (8) (9) (10) (11)
Valve spring (Outer) Retainer Retainer key Shim Valve lifter (Intake)
(12) (13) (14) (15) (16)
Exhaust valve guide Exhaust valve stem seal Valve spring Valve lifter (Exhaust) Cylinder head
ME(H6DO)-10
General Description
MECHANICAL
6. CYLINDER BLOCK
T3 (1) T8
(19) (3) (20)
T1
(4) (19)
T1
(5) T5 T8 (19) (19) T5 T3 (7) (17) (13) (14) (13) T10 (18) T7 (16) (5) T2 T2 (13) (14) (13) (22) (15) (13) (13) (14) T1 T6 (11) T1 ME-03327 (23) T6 (10) T1 T2 (8) (9) T9 (21) (5) (19) T1 T2 (19) (19) T4 T2 (19) (5) (5) T8 (2)
(6)
T2
T4
(24)
(13)
(14) T4
(12)
ME(H6DO)-11
General Description
MECHANICAL
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Cylinder block (RH) Cylinder block (LH) Rear oil seal Service hole cover O-ring Oil pan upper Oil pressure switch Oil strainer Magnet Oil pan lower Metal gasket Drain plug (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) Clamp Hose Oil cooler pipe Oil cooler Oil cooler connector Oil filter Plug Crankshaft position sensor holder Relief valve Relief valve spring Plug Water pipe Tightening torque:Nm (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 18 (1.8, 13.3) T3: 25 (2.5, 18.4) T4: 16 (1.6, 11.8) T5: 37 (3.8, 27.3) T6: 44 (4.5, 32.5) T7: 54 (5.5, 39.8) T8: 70 (7.1, 51.6) T9: 23 (2.3, 17.0) T10: 90 (9.2, 66.4)
ME(H6DO)-12
General Description
MECHANICAL
T1 (7) (12) T2 (13) (4) (5) (6) (7) (8) (10) (15) (11) (13) (6) (12) (18) (16) (17) (16) (17) (16) (17) T1 (7) (9) (5) (4) (11) (3) (11) (10) (8) (7) (1) (9) (14)
(2)
ME-02454
(1) (2) (3) (4) (5) (6) (7) (8)
Reinforcement Drive plate Crankshaft sensor plate Top ring Second ring Oil ring Snap ring Piston
(9) (10) (11) (12) (13) (14) (15)
Piston pin Connecting rod Connecting rod bearing Connecting rod bolt Connecting rod cap Crankshaft Woodruff key
(16) (17) (18)
Crankshaft bearing #1, #3, #5 Crankshaft bearing #2, #4, #6 Crankshaft bearing #7
ME(H6DO)-13
General Description
MECHANICAL
8. ENGINE MOUNTING
(1)
T1
T2
T1
T2
ME-00445
(1)
ME(H6DO)-14
General Description
MECHANICAL
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. All removed parts, if to be reused, should be reinstalled in the original positions and directions. Bolts, nuts and washers should be replaced with new parts as required. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. Lift up or lower the vehicle when necessary. Make sure to support the correct positions.
ME(H6DO)-15
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 18250AA010 DESCRIPTION CYLINDER HEAD TABLE REMARKS Used for replacing valve guides. Used for removing and installing valve spring.
ST18250AA010
18232AA000
ENGINE STAND
Used for disassembling and assembling engine.
ST18232AA000
498497100
CRANKSHAFT STOPPER
Used for removing and installing the drive plate.
ST-498497100
18254AA000
PISTON GUIDE
Used for installing piston in cylinder.
ST18254AA000
ME(H6DO)-16
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499585500 DESCRIPTION VALVE OIL SEAL GUIDE REMARKS Used for press-fitting of intake and exhaust valve guide oil seals.
ST-499585500
18253AA000
PISTON PIN GUIDE
Used for installing piston pin, piston and connecting rod.
ST18253AA000
18350AA000
ST18350AA000
499097700
PISTON PIN REMOVER ASSY
Used for removing piston pin.
ST-499097700
499977500
CAM SPROCKET WRENCH
ST-499977500
ME(H6DO)-17
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 18231AA020 DESCRIPTION CAM SPROCKET WRENCH REMARKS Used for removing and installing exhaust cam sprocket.
ST18231AA020
499587200
ST-499587200
499597100
ST-499597100
499718000
VALVE SPRING REMOVER
Used for removing and installing valve spring.
ST-499718000
18251AA040
Used for installing valve guides.
ST18251AA040
ME(H6DO)-18
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 499765700 DESCRIPTION VALVE GUIDE REMOVER REMARKS Used for removing valve guides.
ST-499765700
499765900
VALVE GUIDE REAMER
ST-499765900
499977100
CRANK PULLEY WRENCH
Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts.
ST-499977100
18252AA000
CRANKSHAFT SOCKET
ST18252AA000
1B022XU0
ST1B022XU0
ME(H6DO)-19
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 18233AA000 DESCRIPTION PISTON PIN SNAP RING PLIERS REMARKS Used for removing and installing snap ring of piston pin.
ST18233AA000
498277200
STOPPER SET
Used for installing automatic transmission assembly to engine.
ST-498277200
499057000
TORX PLUS
Used for removing and installing the drive plate.
ST-499057000
42099AE000
Used for disconnecting quick connector of the engine compartment.
ST42099AE000
18471AA000
FUEL PIPE ADAPTER
Used for measuring fuel pressure.
ST18471AA000
ME(H6DO)-20
General Description
MECHANICAL
ILLUSTRATION TOOL NUMBER 42075AG690 DESCRIPTION FUEL HOSE REMARKS Used for measuring fuel pressure. This is the SUBARU genuine part.
ST42075AG690
2. GENERAL TOOL
TOOL NAME Compression gauge Timing light Vacuum gauge Oil pressure gauge Fuel pressure gauge REMARKS Used for measuring compression. Used for measuring ignition timing. Used for measuring intake manifold vacuum. Used for measuring engine oil pressure. Used for measuring fuel pressure.
E: PROCEDURE
It is possible to conduct the following service procedures with engine on vehicle, however, the procedures described in this section are based on the condition that the engine is removed from vehicle. V-belt Timing chain Camshaft Cylinder head
ME(H6DO)-21
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) Remove the collector cover. 2) After warming-up the engine, turn the ignition switch to OFF. 3) Make sure that the battery is fully charged. 4) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 5) Remove all the spark plugs. <Ref. to IG(H6DO)4, REMOVAL, Spark Plug.> 6) Fully open the throttle valve. 7) Check the starter motor for satisfactory performance and operation. 8) Secure the compression gauge tightly against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long. 9) Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady.
ME-00446
10) Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 rpm and fully open throttle): Standard: 1,275 1,471 kPa (13.0 15.0 kgf/cm2, 185 213 psi) Service limit: 1,128 kPa (11.5 kgf/cm2, 164 psi) 11) After inspection, install the related parts in the reverse order of removal.
ME(H6DO)-22
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the following item: (1) Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the engine idle speed using Subaru Select Monitor. <Ref. to EN(H6DO)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> 4) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF) Idle speed [No load and gears in P or N range]: 650r50 rpm 5) Check the idle speed when loaded. (Turn the A/C switch to ON and operate the compressor for at least one minute before measurement.) Idle speed [A/C ON and gears in P or N range]: 770r50 rpm NOTE: Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to the General On-board Diagnosis Table under Engine Control System. <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
ME(H6DO)-23
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement.
1. METHOD WITH SUBARU SELECT MONITOR

1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the ignition timing using Subaru Select Monitor. <Ref. to EN(H6DO)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> Ignition timing [BTDC/rpm]: 15r8/650 If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
2. METHOD WITH TIMING LIGHT

1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Stop the engine, and turn the ignition switch to OFF. 4) Remove the air cleaner case. <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.> 5) Connect the timing light to the power wire of #1 ignition coil. 6) Install the air cleaner case. <Ref. to IN(H6DO)-6, INSTALLATION, Air Cleaner Case.> 7) Start the engine, aim the timing light to the crank pulley, and check the ignition timing by the crank pulley indicator. Ignition timing [BTDC/rpm]: 15r8/650 If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
ME(H6DO)-24

MECHANICAL

A: INSPECTION
1) Warm up the engine. 2) Disconnect the brake booster vacuum hose from the intake manifold, and install the vacuum gauge. 3) Keep the engine at idle speed and read the vacuum gauge indication. By observing the vacuum gauge needle movement, internal condition of the engine can be diagnosed as described below.
ME-02383
Vacuum pressure (at idling, A/C OFF): Less than 60.0 kPa (450 mmHg, 17.72 inHg)
Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than normal position. This tendency Air leakage around intake manifold gasket, disconnection becomes more evident as engine temperature rises. or damage of vacuum hose 2. Needle intermittently drops to position lower than normal position. Leakage around cylinder 3. Needle drops suddenly and intermittently from normal position. Sticky valve 4. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 5. Needle vibrates above and below normal position in narrow range. Defective ignition system
ME(H6DO)-25
Engine Oil Pressure

MECHANICAL

A: INSPECTION
1) Remove the oil pressure switch from the cylinder block. <Ref. to LU(H6DO)-15, REMOVAL, Oil Pressure Switch.> 2) Connect the oil pressure gauge hose to the cylinder block. 3) Connect the ground cable to battery. 4) Start the engine, and measure the oil pressure. OIL PRESSURE (at oil temperature of 80C (176F)): Standard: 135 kPa (1.4 kgf/cm2, 20 psi) or more (at 600 rpm) 500 kPa (5.1 kgf/cm2, 73 psi) or more (at 5,000 rpm) If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. <Ref. to LU(H6DO)-19, INSPECTION, Engine Lubrication System Trouble in General.> If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch. <Ref. to LU(H6DO)-19, INSPECTION, Engine Lubrication System Trouble in General.> 5) After measuring the oil pressure, install the oil pressure switch. <Ref. to LU(H6DO)-15, INSTALLATION, Oil Pressure Switch.>
ME(H6DO)-26
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
CAUTION: Before removing the fuel pressure gauge, release the fuel pressure. Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. NOTE: Check or replace the fuel pump and fuel delivery line if the fuel pressure is out of the standard. 1) Remove the collector cover. 2) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Open the fuel filler lid, and remove the fuel filler cap. 4) Disconnect the fuel delivery hose and connect the fuel pressure gauge. (1) Disconnect the fuel delivery hose using the ST1. ST1 42099AE000 QUICK CONNECTOR RELEASE
5) Start the engine. 6) Measure the fuel pressure after warming up the engine. Fuel pressure: Standard: 338 348 kPa (3.4 3.5 kgf/cm2, 49 50.5 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
ST
FU-02676
(2) Connect the fuel pressure gauge with ST2 and ST3. NOTE: ST2 is a SUBARU genuine part. ST2 42075AG690 FUEL HOSE ST3 18471AA000 FUEL PIPE ADAPTER
(A) (B)
ME-02666
(A) ST2 (B) ST3
ME(H6DO)-27
Valve Clearance
MECHANICAL
8. Valve Clearance
A: INSPECTION
NOTE: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Disconnect the ground cable from the battery.
8) When inspecting LH side cylinders: (1) Disconnect the battery cable, and then remove the battery and battery carrier. (2) Disconnect the PCV hose and blow-by hose from the rocker cover (LH).
ME-00460
(3) Remove the fuel pipe protector (LH).
IN-00203
4) Lift up the vehicle. 5) Remove the under cover. 6) Lower the vehicle. 7) When inspecting RH side cylinders: (1) Remove the air intake duct and air cleaner case. <Ref. to IN(H6DO)-8, REMOVAL, Air Intake Duct.> <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.> (2) Remove the fuel pipe protector (RH).
FU-02117
(4) Remove the ignition coil. <Ref. IG(H6DO)-7, REMOVAL, Ignition Coil.> (5) Remove the rocker cover (LH).
to
FU-02119
(3) Disconnect the connector of oil pressure switch. (4) Remove the ignition coil. <Ref. to IG(H6DO)-7, REMOVAL, Ignition Coil.> (5) Remove the rocker cover (RH).
ME(H6DO)-28
Valve Clearance
MECHANICAL
9) Turn the crankshaft clockwise until the cam is set to position shown in the figure.
10) Measure the clearance of intake valve and exhaust valve using thickness gauge (A). NOTE: Measure it within the range of r30 from specified position shown in the figure. Measure it in low lift cam for intake side. Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter. Valve clearance Intake: 0.20+0.04 0.06 mm (0.0079+0.0016 0.0024 in) Exhaust: 0.35r0.05 mm (0.0138r0.0020 in) If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on.
(3) (4)
(4) (3)
(23 ) (1) (1)
(23 )
(2)
(2)
(A)
ME-02565
(1) (2) (3) (4)
Valve clearance (Intake side) Valve clearance (Exhaust side) High lift cam Low lift cam
ME-00464
11) If necessary, adjust the valve clearance. <Ref. to ME(H6DO)-30, ADJUSTMENT, Valve Clearance.> 12) Further turn the crank pulley clockwise and then measure the valve clearances again. 13) After inspection, install the related parts in the reverse order of removal.
ME(H6DO)-29
Valve Clearance
MECHANICAL
B: ADJUSTMENT
1. INTAKE SIDE
NOTE: Adjustment of valve clearance should be performed while engine is cold. Do not wear gloves during removal and installation of valve lifter. Do not use valve lifters that were dropped or otherwise exposed to strong impacts. When installing the valve lifter, align the anti-rotation of valve lifter with groove on cylinder head, and insert the valve lifter. 1) Measure all the valve clearances. <Ref. to ME(H6DO)-28, INSPECTION, Valve Clearance.> NOTE: Record each valve clearance after measurement. 2) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 3) Remove the cam sprocket. <Ref. to ME(H6DO)51, REMOVAL, Cam Sprocket.> 4) Remove the camshaft. <Ref. to ME(H6DO)-55, REMOVAL, Camshaft.> 5) Remove the valve lifter. 6) Remove the shim from valve lifter. 7) Check the thickness of the shim from the markings on the side of the shim that was removed. 8) Select a shim of suitable thickness from the following table using the measured valve clearance and shim thickness, and install it.
Unit: mm (in) S = (V + T) 0.20 (0.0079) S: Required shim thickness V: Measured valve clearance T: Shim thickness to be used
Part No. 13218AK890 13218AK900 13218AK910 13218AK920 13218AK930 13218AK940 13218AK950 13218AK960 13218AK970 13218AK980 13218AK990 13218AL000 13218AL010 13218AL020 13218AL030 13218AL040 13218AL050 13218AL060 13218AL070 13218AL080 13218AL090 13218AL100 13218AL110 13218AL120 13218AL130 13218AL140 13218AL150 13218AL160 13218AL170 13218AL180 13218AL190 13218AL200 13218AL210 13218AL220 13218AL230 13218AL240 13218AL250 13218AL260 13218AL270 13218AL280 13218AL290 13218AL300 13218AL310 13218AL320 13218AL330 13218AL340 13218AL350 13218AL360 13218AL370 13218AL380
Thickness mm (in) 1.92 (0.0756) 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.07 (0.0815) 2.08 (0.0819) 2.09 (0.0823) 2.10 (0.0827) 2.11 (0.0831) 2.12 (0.0835) 2.13 (0.0839) 2.14 (0.0843) 2.15 (0.0846) 2.16 (0.0850) 2.17 (0.0854) 2.18 (0.0858) 2.19 (0.0862) 2.20 (0.0866) 2.21 (0.0870) 2.22 (0.0874) 2.23 (0.0878) 2.24 (0.0882) 2.25 (0.0886) 2.26 (0.0890) 2.27 (0.0894) 2.28 (0.0898) 2.29 (0.0902) 2.30 (0.0906) 2.31 (0.0909) 2.32 (0.0913) 2.33 (0.0917) 2.34 (0.0921) 2.35 (0.0925) 2.36 (0.0929) 2.37 (0.0933) 2.38 (0.0937) 2.39 (0.0941) 2.40 (0.0945) 2.41 (0.0949) 2.42 (0.0953) 2.43 (0.0957) 2.44 (0.0961) 2.45 (0.0965) 2.46 (0.0969) 2.47 (0.0972) 2.48 (0.0976)
ME(H6DO)-30
Valve Clearance
MECHANICAL
Part No. 13218AL390 13218AL400 13218AL410 13218AL420 13218AL430 13218AL440 13218AL450 13218AL460 13218AL470 13218AL480 13218AL490 13218AL500 13218AL510 13218AL520 13218AL530 13218AL540 13218AL550 13218AL560 13218AL570 13218AL580 13218AL590 Thickness mm (in) 2.49 (0.0980) 2.50 (0.0984) 2.51 (0.0988) 2.52 (0.0992) 2.53 (0.0996) 2.54 (0.1000) 2.55 (0.1004) 2.56 (0.1008) 2.57 (0.1012) 2.58 (0.1016) 2.59 (0.1020) 2.60 (0.1024) 2.61 (0.1028) 2.62 (0.1032) 2.64 (0.1039) 2.66 (0.1047) 2.68 (0.1055) 2.70 (0.1063) 2.72 (0.1071) 2.74 (0.1079) 2.76 (0.1087)
2. EXHAUST SIDE
NOTE: Adjustment of valve clearance should be performed while engine is cold. Do not wear gloves during removal and installation of valve lifter. Do not use valve lifters that were dropped or otherwise exposed to strong impacts. 1) Measure all the valve clearances. <Ref. to ME(H6DO)-28, INSPECTION, Valve Clearance.> NOTE: Record each valve clearance after measurement. 2) Remove the camshaft. <Ref. to ME(H6DO)-55, REMOVAL, Camshaft.> 3) Remove the valve lifter. 4) Measure the thickness of valve lifter using micrometer.
9) Install the camshaft. <Ref. to ME(H6DO)-56, INSTALLATION, Camshaft.> 10) Install the cam sprocket. <Ref. to ME(H6DO)51, INSTALLATION, Cam Sprocket.> 11) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 12) Measure all valve clearance again at this time. If the valve clearance is not correct, repeat the procedure over again from the first step. 13) After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.
ME-00025
5) Select a valve lifter of suitable thickness from the following table using the measured valve clearance and valve lifter thickness, and install it.
Unit: mm (in) S = (V + T) 0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used
ME(H6DO)-31
Valve Clearance
MECHANICAL
Part No. 13228AD181 13228AD191 13228AD201 13228AD211 13228AD221 13228AD231 13228AD241 13228AD251 13228AD261 13228AD271 13228AD281 13228AD291 13228AD301 13228AD311 13228AD321 13228AC581 13228AC591 13228AC601 13228AC611 13228AC621 13228AC631 13228AC641 13228AC651 13228AC661 13228AC671 13228AC681 13228AC691 13228AC701 13228AC711 13228AC721 13228AC731 13228AC741 13228AC751 13228AC761 13228AC771 13228AC781 13228AC791 13228AC801 13228AC811 13228AC821 13228AC831 13228AC841 13228AC851 13228AC861 13228AC871 13228AC881 13228AC891 13228AC901 13228AC911 13228AC921 Thickness mm (in) 4.32 (0.1701) 4.34 (0.1709) 4.36 (0.1717) 4.38 (0.1724) 4.40 (0.1732) 4.42 (0.1740) 4.44 (0.1748) 4.46 (0.1756) 4.48 (0.1764) 4.50 (0.1772) 4.52 (0.1780) 4.54 (0.1787) 4.56 (0.1795) 4.58 (0.1803) 4.60 (0.1811) 4.62 (0.1819) 4.63 (0.1823) 4.64 (0.1827) 4.65 (0.1831) 4.66 (0.1835) 4.67 (0.1839) 4.68 (0.1843) 4.69 (0.1846) 4.70 (0.1850) 4.71 (0.1854) 4.72 (0.1858) 4.73 (0.1862) 4.74 (0.1866) 4.75 (0.1870) 4.76 (0.1874) 4.77 (0.1878) 4.78 (0.1882) 4.79 (0.1886) 4.80 (0.1890) 4.81 (0.1894) 4.82 (0.1898) 4.83 (0.1902) 4.84 (0.1906) 4.85 (0.1909) 4.86 (0.1913) 4.87 (0.1917) 4.88 (0.1921) 4.89 (0.1925) 4.90 (0.1929) 4.91 (0.1933) 4.92 (0.1937) 4.93 (0.1941) 4.94 (0.1945) 4.95 (0.1949) 4.96 (0.1953) Part No. 13228AC931 13228AC941 13228AC951 13228AC961 13228AC971 13228AC981 13228AC991 13228AD001 13228AD011 13228AD021 13228AD031 13228AD041 13228AD051 13228AD061 13228AD071 13228AD081 13228AD091 13228AD101 13228AD111 13228AD121 13228AD131 13228AD141 13228AD151 13228AD161 13228AD171 13228AD331 13228AD341 13228AD351 13228AD361 13228AD371 13228AD381 13228AD391 13228AD401 13228AD411 13228AD421 13228AD431 13228AD441 13228AD451 13228AD461 13228AD471 13228AD481 13228AD491 13228AD501 13228AD511 Thickness mm (in) 4.97 (0.1957) 4.98 (0.1961) 4.99 (0.1965) 5.00 (0.1969) 5.01 (0.1972) 5.02 (0.1976) 5.03 (0.1980) 5.04 (0.1984) 5.05 (0.1988) 5.06 (0.1992) 5.07 (0.1996) 5.08 (0.2000) 5.09 (0.2004) 5.10 (0.2008) 5.11 (0.2012) 5.12 (0.2016) 5.13 (0.2020) 5.14 (0.2024) 5.15 (0.2028) 5.16 (0.2032) 5.17 (0.2035) 5.18 (0.2039) 5.19 (0.2043) 5.20 (0.2047) 5.21 (0.2051) 5.23 (0.2059) 5.25 (0.2067) 5.27 (0.2075) 5.29 (0.2083) 5.31 (0.2091) 5.33 (0.2098) 5.35 (0.2106) 5.37 (0.2114) 5.39 (0.2122) 5.41 (0.2130) 5.43 (0.2138) 5.45 (0.2146) 5.47 (0.2154) 5.49 (0.2161) 5.51 (0.2169) 5.53 (0.2177) 5.55 (0.2185) 5.57 (0.2193) 5.59 (0.2201)
ME(H6DO)-32
Valve Clearance
MECHANICAL
6) Install the camshaft. <Ref. to ME(H6DO)-56, INSTALLATION, Camshaft.> 7) Install the cam sprocket. <Ref. to ME(H6DO)-51, INSTALLATION, Cam Sprocket.> 8) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 9) Measure all valve clearance again at this time. If the valve clearance is not correct, repeat the procedure over again from the first step. 10) After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.
ME(H6DO)-33
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift. 2) Open the front hood fully and support with the front hood stay. 3) Remove the collector cover. 4) Collect the refrigerant from A/C system. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 5) Release the fuel pressure. <Ref. to FU(H6DO)43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 6) Remove the fuel filler cap. 7) Remove the battery from vehicle. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 8) Remove the air intake duct, air cleaner case and air intake chamber. <Ref. to IN(H6DO)-8, REMOVAL, Air Intake Duct.> <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.> <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 9) Remove the radiator from vehicle. <Ref. to CO(H6DO)-15, REMOVAL, Radiator.> 10) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 11) Disconnect the A/C pressure hoses from A/C compressor. <Ref. to AC-40, REMOVAL, Hose and Pipe.> 12) Disconnect the engine ground terminals.
ME-02383
(2) Heater inlet and outlet hoses (3) Pressure regulator vacuum hose 15) Remove the power steering pump together with the bracket. NOTE: Do not disconnect the hose and pipe from the pump body.
ME-02992
ME-00476
13) Disconnect the following connector. (1) Engine harness connectors
ME-02990
16) Place the power steering pump on the right side wheel apron.
(A)
ME-02382
(2) Generator connector and terminal (3) A/C compressor connector (4) Power steering switch connector
ME-00483
(A) Cloth
ME(H6DO)-34
Engine Assembly
MECHANICAL
17) Lift up the vehicle. 18) Remove the under cover. 19) Remove the front exhaust pipe. <Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.> NOTE: Be careful not to let the front exhaust pipe interfere with water pipes on engine side. 20) Remove the ground cable.
24) Separate the torque converter clutch from drive plate. (1) Remove the service hole plug (A). (2) Remove the bolts which hold torque converter clutch to drive plate. (3) Remove other bolts while rotating the crankshaft using socket wrench.
ME-02027
21) Remove the bolts and nuts which hold lower side of transmission to engine.
(A)
ME-02445

AT-03238
22) Remove the nuts which install front cushion rubber onto front crossmember.
ME-03286
ME-00485
ME(H6DO)-35
Engine Assembly
MECHANICAL
26) Disconnect the fuel delivery hose and evaporation hose. CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. (1) Disconnect the connector of fuel pipe by pushing the ST in the direction of arrow. ST 42099AE000 QUICK CONNECTOR RELEASE (2) Remove the clip, and disconnect the evaporation hose from the pipe.
29) Separate the engine and transmission. (1) Remove the starter. <Ref. to SC(H4SO)-6, REMOVAL, Starter.> (2) Remove the bolts which hold upper side of transmission to engine.
AT-03237
30) Attach the ST to the converter case. ST 498277200 STOPPER SET

ST
FU-02866
27) Support the engine with a lifting device and wire ropes. 28) Support the transmission with a garage jack. CAUTION: Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
ST ME-00492
31) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. (3) Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 32) Remove the engine mounting.
(A) (B)
ME-00490
CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked.
ME(H6DO)-36
Engine Assembly
MECHANICAL
B: INSTALLATION
1) Install the engine mounting. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb) 2) Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 3) Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
(2) Tighten other bolts while rotating the crankshaft using socket wrench. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) (3) Install the service hole plug (A) to prevent getting foreign matter inside.
(A) AT-03237
4) Remove the lifting device and wire ropes. 5) Remove the garage jack. 6) Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb) 10) Install the power steering pump. Tightening torque: (A): 25 Nm (2.5 kgf-m, 18.4 ft-lb) (B): 33 Nm (3.4 kgf-m, 24.3 ft-lb)
(A)
ME-02445
T2 T1 ME-03287 (B) ME-02993
7) Remove the ST from converter case. NOTE: Be careful not to drop the ST into the converter case when removing the ST. ST 498277200 STOPPER SET 8) Install the starter. <Ref. to SC(H4SO)-6, INSTALLATION, Starter.> 9) Install the torque converter clutch to drive plate. (1) Tighten the bolts which hold torque converter clutch to drive plate.
(B)
(B)
ME-02991
11) Lift up the vehicle.
ME(H6DO)-37
Engine Assembly
MECHANICAL
12) Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
18) Connect the following hoses. (1) Fuel delivery hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose (4) Pressure regulator vacuum hose 19) Connect the following connectors. (1) Engine harness connectors
AT-03238
13) Tighten the nuts which install the front cushion rubber onto crossmember. Tightening torque: 85 Nm (8.7 kgf-m, 62.7 ft-lb) NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
ME-02382
(2) Generator connector and terminal (3) A/C compressor connector (4) Power steering switch connector 20) Install the engine ground terminals. Tightening torque: 14 Nm (1.4 kgf-m, 10.3 ft-lb)
(B) (A)
(A) (B)
ME-00494 ME-00476
14) Install the front exhaust pipe. <Ref. to EX(H6DO)-5, INSTALLATION, Front Exhaust Pipe.> NOTE: Be care not to let the front exhaust pipe interfere with water pipes and crossmember on engine side. Be care not to scratch the flange surface of front exhaust pipe with stud bolt on engine. 15) Connect the ground cable.
ME-02027
16) Install the under cover. 17) Lower the vehicle.
21) Install the A/C pressure hoses. <Ref. to AC-40, INSTALLATION, Hose and Pipe.> 22) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.> 23) Install the radiator to vehicle. <Ref. to CO(H6DO)-16, INSTALLATION, Radiator.> 24) Install the air intake duct, air cleaner case and air intake chamber. <Ref. to IN(H6DO)-8, INSTALLATION, Air Intake Duct.> <Ref. to IN(H6DO)-6, INSTALLATION, Air Cleaner Case.> <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.> 25) Install the battery to the vehicle. <Ref. to SC(H4SO)-20, INSTALLATION, Battery.> 26) Fill engine coolant. <Ref. to CO(H6DO)-10, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 27) Check the ATF level and replenish it if necessary. <Ref. to 5AT-28, INSPECTION, Automatic Transmission Fluid.>
ME(H6DO)-38
Engine Assembly
MECHANICAL
28) Charge the A/C system with refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.> 29) Install the collector cover. 30) Remove the front hood stay, and close the front hood. 31) Lower the vehicle from lift.
C: INSPECTION
1) Check the pipes and hoses are installed firmly. 2) Check the engine coolant and ATF are at specified levels. 3) Start the engine and check for leaks of fuel, exhaust gas, engine coolant, etc. Also check for noise and vibrations.
ME(H6DO)-39
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H6DO)34, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Engine mounting: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
ME(H6DO)-40

MECHANICAL

A: REMOVAL
1) Remove the engine from the body. <Ref. to ME(H6DO)-34, REMOVAL, Engine Assembly.> 2) Set the engine on ST. ST 18232AA000 ENGINE STAND
ST ME-02448
3) Before servicing overhaul, remove the sensor, pipe and hose that installed to engine. (1) Remove the intake manifold. <Ref. to FU(H6DO)-14, REMOVAL, Intake Manifold.> (2) Remove the generator. <Ref. to SC(H4SO)14, REMOVAL, Generator.> (3) Remove the A/C compressor. <Ref. to AC36, REMOVAL, Compressor.> (4) Disconnect the water pipe and hose. (5) Disconnect the engine harness. (6) Remove the spark plug. <Ref. to IG(H6DO)4, REMOVAL, Spark Plug.> (7) Remove the camshaft position sensor. <Ref. to FU(H6DO)-22, REMOVAL, Camshaft Position Sensor.> (8) Remove the crankshaft position sensor. <Ref. to FU(H6DO)-21, REMOVAL, Crankshaft Position Sensor.> (9) Remove the knock sensor. <Ref. to FU(H6DO)-23, REMOVAL, Knock Sensor.> (10) Remove the engine coolant temperature sensor. <Ref. to FU(H6DO)-20, REMOVAL, Engine Coolant Temperature Sensor.> (11) Remove the oil pressure switch. <Ref. to LU(H6DO)-15, REMOVAL, Oil Pressure Switch.> (12) Remove the oil filter. <Ref. to LU(H6DO)16, REMOVAL, Engine Oil Filter.> (13) Remove the oil cooler. <Ref. to LU(H6DO)17, REMOVAL, Oil Cooler.>
ME(H6DO)-41
V-belt
MECHANICAL
12.V-belt
A: REMOVAL
NOTE: Perform the work with the engine installed to body when replacing a single part. 1) Remove the collector cover. 2) Install the tool to belt tension adjuster assembly installation bolt. 3) Rotate the tool clockwise and loosen the V-belt to remove.
C: INSPECTION
1) Replace the V-belt, if cracks, fraying or wear is found. 2) Make sure that the V-belt automatic belt tension indicator (A) is within the range (D).
(A)
(D)
(C) (B)
ME-00473
B: INSTALLATION
(1) (6) ME-00475
(4)
(A) (B) (C) (D)
Indicator Generator Power steering oil pump pulley Service limit
(2) (3)
(5)
ME-00474
(1) (2) (3) (4) (5) (6)
Power steering oil pump pulley Belt tension adjuster ASSY Crank pulley A/C compressor pulley Belt idler Generator pulley
ME(H6DO)-42
Crank Pulley
MECHANICAL
13.Crank Pulley
A: REMOVAL
NOTE: Perform the work with the engine installed to body when replacing a single part. 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley cover.
B: INSTALLATION
1) Install the crank pulley. 2) Install the crank pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH (1) Clean the crankshaft thread using compressed air. (2) Apply engine oil to the crank pulley bolt seat and thread. (3) Tighten the crank pulley bolts. Tightening torque: 178 Nm (18.1 kgf-m, 131.3 ft-lb)
ME-02028
3) Remove the crank pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH 3) Install the crank pulley cover. NOTE: Use new O-rings. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
ST ME-02598
ME-00497
ME-02028
4) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the crank pulley cover for oil and air leakage. 2) Check the crank pulley for looseness.
ME(H6DO)-43
Front Chain Cover

MECHANICAL
14.Front Chain Cover

A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the bolts which install oil pipe (RH) onto the front chain cover. 4) Remove the front chain cover. NOTE: Chain cover installation bolt has three different sizes. To prevent the confusion in installation, keep these bolts on container individually.
(A) (C)
B: INSTALLATION
1) Remove the used liquid gasket from mating surface, and degrease it. 2) Apply liquid gasket to the mating surface of front chain cover. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter 2.5r0.5 mm (0.098r0.020 in)
(B)
ME-02385 (C) (A) (B)
3) Install the front chain cover. Temporarily tighten the bolts.

ME-02029
CAUTION: Do not install the bolts in wrong place.

(A) (C)
(A) (B) (C) *:
M6 16 M6 30 M6 45 Sealing washer
(B)
(C) (A) (B)
ME-02029
(A) (B) (C) *:
M6 16 M6 30 M6 45 Sealing washer
ME(H6DO)-44
Front Chain Cover

MECHANICAL
4) Tighten the bolts in the numerical order as shown in the figure. Tightening torque: 6.6 Nm (0.7 kgf-m, 4.9 ft-lb)
(25) (24) (23) (9) (10) (8) (26) (27) (4) (28) (2) (7) (5) (6) (3) (1) (36) (37) (33) (11) (12) (13) (32) (34) (35)
(38)
(19) (29) (30) (31) (18) (17) (16) (15) (14) (20) (21) ME-02031 (22) (40) (39)
5) Tighten the bolts which install oil pipe (RH) onto the front chain cover. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) 6) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 7) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
C: INSPECTION
Check the cover surface for scratch and damage. Check for oil leakage on cover mating surface and installation part of crank pulley.
ME(H6DO)-45
Timing Chain Assembly

MECHANICAL
15.Timing Chain Assembly

A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 4) Remove the chain tensioner (RH). NOTE: Be careful not to let the plunger (A) pops out.
9) Remove the chain tensioner (LH). NOTE: Be careful not to let the plunger pops out.
ME-02034
10) Remove the chain tensioner lever (LH).
(A)
ME-02035 ME-00501
5) Remove the chain guide (RH: between cams).
11) Remove the chain guide (LH: between cams).
ME-02036 ME-02032
6) Remove the chain guide (RH). 7) Remove the chain tensioner lever (RH).
(A)
12) Remove the chain guide (LH).
(B) ME-02033
ME-02037
(A) Chain guide (RH) (B) Chain tensioner lever (RH)
8) Remove the timing chain (RH).
ME(H6DO)-46

MECHANICAL
13) Remove the chain guide (center).
B: INSTALLATION
NOTE: Be careful that the foreign matter is not into or onto assembled component during installation. Apply engine oil to the chain guide, chain tensioner lever and idler sprocket when installing. 1) Prepare to attach the chain tensioner. (1) Insert the screw, spring pin and tension rod into tensioner body. (2) While depressing the tensioner onto rubber mat, twist it to shorten tension rod. Then insert the thin pin into the hole between tension rod and tension body to keep it. NOTE: Work on the rubber mat or other anti-skid materials.
ME-02038
14) Remove the idler sprocket (upper).
ME-02039
15) Remove the timing chain (LH). 16) Remove the idler sprocket (lower).
ME-00511
2) Using the ST, align the Top mark on crank sprocket to 9 oclock position as shown in the figure. ST 18252AA000 CRANKSHAFT SOCKET
ME-00510
ME-02040
3) Align the key groove on exhaust cam sprocket to 12 oclock position as shown in the figure.
ME-02041
ME(H6DO)-47

MECHANICAL
4) Align the intake cam sprocket as shown in the figure.

RH (A) (B) (C) LH
(2) Install the timing chain (LH) to the idler sprocket (lower), water pump, exhaust cam sprocket (LH) and intake cam sprocket (LH) in this order. NOTE: Check that the mark on timing chain (A) and cam sprocket (B) is aligned as same as aligned on crank sprocket.
ME-02456
(A) (B)
(A) Top mark (B) 40 (C) 15
5) Turn the crank sprocket clockwise, align the Top mark to 12 oclock position. (Piston #1 is in TDC position) NOTE: Do not rotate the crank shaft and cam sprocket before completing the installation of timing chain. 6) Install the idler sprocket (lower). Tightening torque: 69 Nm (7.0 kgf-m, 50.9 ft-lb)
(A) ME-02043
(B)
(A) Blue (B) Mark
(3) Install the idler sprocket (upper).

ME-00510
7) Install the timing chain (LH). (1) Align the timing mark (B) on the crank sprocket with mark (A) on the timing chain (LH).
(A)
ME-02039 (B) ME-00515
(A) Gold (B) Mark
ME(H6DO)-48

MECHANICAL
(4) Install the chain guide (LH: between cams). Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) NOTE: Use a new installing bolt.
(7) Install the chain tensioner (LH). Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
ME-02034
ME-02036
(5) Install the chain guide (LH). Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
8) Install the timing chain (RH). (1) Align the marks of timing chain LH and RH on the idler sprocket (lower).
(B) (A)
(C)
(D)
ME-00518
ME-02037
(6) Install the chain tensioner lever (LH). Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
(A) (B) (C) (D)
Idler sprocket (lower) Timing chain (RH) Timing chain (LH) Blue
ME-02035
ME(H6DO)-49

MECHANICAL
(2) Install the timing chain (RH) to the intake cam sprocket (RH) and exhaust cam sprocket (RH) in this order. NOTE: Check that the mark on timing chain (A) and cam sprocket (B) is aligned as same as aligned on crank sprocket.
(A)
NOTE: Use a new installing bolt.
ME-02032 (B)
(6) Install the chain tensioner (RH). Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
(B)
(A) ME-00520
ME-02044
(A) Gold (B) Mark
(7) Adjust the clearance between chain guide (RH) and chain guide (center) within 8.4 8.6 mm (0.331 0.339 in). Install the chain guide (center). Tightening torque: 7.8 Nm (0.8 kgf-m, 5.9 ft-lb) NOTE: Use a new installing bolt.
(3) Install the chain guide (RH). (4) Install the chain tensioner lever (RH). Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
(A)
(B) ME-00521 ME-02033
(A) Chain guide (RH) (B) Chain tensioner lever (RH)
(5) Install the chain guide (RH: between cams). Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(8) Check that each mark on the sprocket and timing chain is matched, and then draw out the stopper pin from chain tensioner. 9) Install the front chain cover. <Ref. to ME(H6DO)44, INSTALLATION, Front Chain Cover.> 10) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 11) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
ME(H6DO)-50
Cam Sprocket
MECHANICAL
16.Cam Sprocket
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 4) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 5) Remove the cam sprocket. To lock the camshaft, use the ST. ST 499977500 CAM SPROCKET WRENCH
B: INSTALLATION
1) Install the cam sprocket. To lock the camshaft, use the ST. Tightening torque: 29.5 Nm (3.0 kgf-m, 21.8 ft-lb) 2) Further tighten the bolts. Tightening angle: Intake side 45r5 Exhaust side 25r5 ST 499977500 CAM SPROCKET WRENCH
ME-02045
ST
18231AA020 CAM SPROCKET WRENCH
ME-02045
ST
18231AA020 CAM SPROCKET WRENCH
ME-02046
ME-02046
3) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 4) Install the front chain cover. <Ref. to ME(H6DO)44, INSTALLATION, Front Chain Cover.> 5) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 6) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the cam sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between cam sprocket and key.
ME(H6DO)-51
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 4) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 5) Remove the crank sprocket (A).
(A)
ME-02047
B: INSTALLATION
1) Install the crank sprocket (A).
(A)
ME-02047
2) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 3) Install the front chain cover. <Ref. to ME(H6DO)44, INSTALLATION, Front Chain Cover.> 4) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 5) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the crank sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between crank sprocket and key.
ME(H6DO)-52
Rear Chain Cover

MECHANICAL
18.Rear Chain Cover

A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 4) Remove the timing chain. <Ref. to ME(H6DO)46, REMOVAL, Timing Chain Assembly.> 5) Remove the cam sprocket. <Ref. to ME(H6DO)51, REMOVAL, Cam Sprocket.> 6) Remove the crank sprocket. <Ref. to ME(H6DO)-52, REMOVAL, Crank Sprocket.> 7) Remove the oil pump. <Ref. to LU(H6DO)-9, REMOVAL, Oil Pump.> 8) Remove the water pump. <Ref. to CO(H6DO)12, REMOVAL, Water Pump.> 9) Remove the rear chain cover. NOTE: Installation bolt has seven different sizes. To prevent the confusion in installation, keep these bolts on container individually.
B: INSTALLATION
NOTE: When replacing the rear chain cover, it is required to select the size. <Ref. to LU(H6DO)-10, INSPECTION, Oil Pump.> 1) Remove the used liquid gasket from mating surface, and degrease it. 2) Apply liquid gasket to the mating surface of rear chain cover. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter (A) 1.0r0.5 mm (0.039r0.020 in) (B) 3.0r1.0 mm (0.118r0.039 in)
(A)
(B)
ME-02049
3) Install the O-ring.

(A) (B) (C) (E) (D)
NOTE: Use new O-rings. Do not install the O-ring in wrong place.
(A) (A)
(G)
(F) ME-02048
(A) (B) (C) (D) (E) (F) (G)
M6 14 M6 18 (Silver) M6 30 M6 18 M8 40 M8 30 M6 22
(D) (C) (B) ME-02457
(A) (B) (C) (D)
14.2 1.9 19.2 2.4 25 2 31.2 1.9
4) Install the water pump gasket. NOTE: Use a new gasket.
ME(H6DO)-53
Rear Chain Cover

MECHANICAL
5) Temporarily tighten the rear chain cover. NOTE: Do not install the bolts in wrong place.
12) Install the front chain cover. <Ref. to ME(H6DO)-44, INSTALLATION, Front Chain Cover.> 13) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 14) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
(A) (B)
(C) (E)
(D)
(G)
(F) ME-02048
(A) (B) (C) (D) (E) (F) (G)
M6 14 M6 18 (Silver) M6 30 M6 18 M8 40 M8 30 M6 22
6) Tighten the bolts in the numerical order as shown in the figure. Tightening torque:
(1) (11) (12) (19) (20) (30) (31) (38) (39) (45) 9 Nm (0.9 kgf-m, 6.6 ft-lb) 20 Nm (2.0 kgf-m, 14.8 ft-lb) 9 Nm (0.9 kgf-m, 6.6 ft-lb) 12 Nm (1.2 kgf-m, 8.9 ft-lb) 9 Nm (0.9 kgf-m, 6.6 ft-lb)
(29) (20) (45) (31)(32) (2) (3) (4) (1) (21) (30) (33) (19) (43) (22) (18) (42) (23) (34) (41) (24) (35) (12) (6) (40) (25) (26) (39) (7) (5) (13) (27) (38) (11) (14) (28) (8) (37) (10) (9) (36) (17) (16) (15) ME-02051 (44)
7) Install the water pump. <Ref. to CO(H6DO)-12, INSTALLATION, Water Pump.> 8) Install the oil pump. <Ref. to LU(H6DO)-9, INSTALLATION, Oil Pump.> 9) Install the crank sprocket. <Ref. to ME(H6DO)52, INSTALLATION, Crank Sprocket.> 10) Install the cam sprocket. <Ref. to ME(H6DO)51, INSTALLATION, Cam Sprocket.> 11) Install the timing chain. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.>
ME(H6DO)-54
Camshaft
MECHANICAL
19.Camshaft
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. Refer to Valve Clearance for preparation procedures. <Ref. to ME(H6DO)-28, Valve Clearance.> 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 4) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 5) Remove the cam sprocket. <Ref. to ME(H6DO)51, REMOVAL, Cam Sprocket.> 6) Remove the crank sprocket. <Ref. to ME(H6DO)-52, REMOVAL, Crank Sprocket.> 7) Remove the rear chain cover. <Ref. to ME(H6DO)-53, REMOVAL, Rear Chain Cover.> 8) Disconnect the oil pipe.
(A)
10) Remove the plugs (LH).
ME-02055
11) Loosen the camshaft cap bolts equally, a little at a time in numerical sequence shown in the figure.
(2) (4)
(7)
(9)
(5)
(8) (14)
(10) (16)
(6) (12)
(3) (1)
(13)
(15)
(11)
ME-02054
12) Remove the camshaft caps and camshaft (LH). NOTE: Arrange camshaft caps in order so that they can be installed in their original positions. 13) Similarly, remove the camshaft (RH) and related parts.
(B) ME-02513
(A) Bolt without filter (without protrusion) (B) Bolt with filter (with protrusion)
9) Remove the rocker cover (LH).
ME-00529
ME(H6DO)-55
Camshaft
MECHANICAL
B: INSTALLATION
1) Apply engine oil to camshaft journals, and install the camshaft. 2) Install the camshaft cap. (1) Apply liquid gasket sparingly to back side of front camshaft cap as shown in the figure. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 2.0r0.5 mm (0.079r0.020 in)
3) Install the plugs. Tightening torque: 60 Nm (6.1 kgf-m, 44.3 ft-lb)
ME-02055
4) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Apply liquid gasket sparingly to the mating surface of cylinder head and rocker cover as shown in the figure. CAUTION: Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure. NOTE: Install within 5 minutes after applying liquid gasket.
ME-02057
(2) Apply engine oil to cap bearing surface, and install the cap to camshaft. (3) Tighten the rocker cover bolts in the numerical order as shown in the figure. Tightening torque: (1) (12): 16 Nm (1.6 kgf-m, 11.8 ft-lb) (13) (16): 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent LH side
(15)
(10)
(8)
(12)
(13)
(9) (3)
(7) (1)
(11) (5)
ME-03940
RH side
(14) (16)
(4)
(2)
(6)
ME-02058
ME-03941
ME(H6DO)-56
Camshaft
MECHANICAL
(3) Tighten the rocker cover bolts in the numerical order as shown in the figure. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) LH side
(10) (1) (3) (7)
(6)
(5)
(9) (8) (4) (2) ME-02061
7) Install the crank sprocket. <Ref. to ME(H6DO)52, INSTALLATION, Crank Sprocket.> 8) Install the cam sprocket. <Ref. to ME(H6DO)-51, INSTALLATION, Cam Sprocket.> 9) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 10) Install the front chain cover. <Ref. to ME(H6DO)-44, INSTALLATION, Front Chain Cover.> 11) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 12) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
C: INSPECTION
1) Measure the bend of camshaft. Repair or replace if bended.
RH side
(8) (1) (3)
Service limit: 0.020 mm (0.00079 in)

(5)
(6) (7)
(10)
(9) (4) (2) ME-03105
5) Connect the oil pipe. NOTE: Be careful not to mistake the location of (A) and (B). Use a new gasket. Tightening torque: (A), (B) 29 Nm (3.0 kgf-m, 21.4 ft-lb) (C) 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(A) ME-00539
2) Check the journal for damage and wear. Replace if faulty. 3) Check the cutout portion used for camshaft sensor for damage. Replace if faulty. 4) Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, check the oil clearance.
Camshaft journal Front Except for front 37.946 37.963 25.946 25.963 (1.4939 1.4946) (1.0215 1.0222)
Standard mm (in)
(C)
(B) ME-02567
(A) Bolt without filter (without protrusion) (B) Bolt with filter (with protrusion) (C) Oil pipe bolt
5) Measurement of the camshaft journal oil clearance: (1) Clean the camshaft cap and cylinder head camshaft journal. (2) Place the camshaft on the cylinder head. (Do not attach the valve rockers.) (3) Place a plastigauge across each camshaft journals. (4) Install the camshaft cap. NOTE: Do not turn the camshaft. (5) Remove the camshaft cap.
6) Install the rear chain cover. <Ref. to ME(H6DO)53, INSTALLATION, Rear Chain Cover.>
ME(H6DO)-57
Camshaft
MECHANICAL
(6) Measure the widest point of the plastigauge on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard: 0.037 0.072 mm (0.0015 0.0028 in)
7) Measure the side clearance of the camshaft with a dial gauge. If the side clearance exceeds the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary replace the camshaft. Standard Intake 0.075 0.135 mm (0.0030 0.0053 in) Exhaust 0.030 0.090 mm (0.0012 0.0035 in)
ME-00119
(7) Completely remove the plastigauge. 6) Check the cam face condition; remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the standard or offset wear occurs, replace it. Cam height H: Standard Intake HIGH 42.09 42.19 mm (1.6571 1.6610 in) LOW1 38.14 38.24 mm (1.5016 1.5055 in) LOW2 38.14 38.24 mm (1.5016 1.5055 in) Exhaust 40.45 40.55 mm (1.5925 1.5965 in) Cam base circle diameter A: Standard Intake HIGH 32.00 mm (1.2598 in) LOW1 31.84 mm (1.2535 in) LOW2 31.84 mm (1.2535 in) Exhaust 32.00 mm (1.2598 in)
ME-00120
ME(H6DO)-58
Cylinder Head
MECHANICAL
20.Cylinder Head
A: REMOVAL
NOTE: When replacing the single part, perform the work with the engine installed to body. Refer to Valve Clearance for preparation procedures. <Ref. to ME(H6DO)-28, Valve Clearance.> 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 4) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 5) Remove the cam sprocket. <Ref. to ME(H6DO)51, REMOVAL, Cam Sprocket.> 6) Remove the crank sprocket. <Ref. to ME(H6DO)-52, REMOVAL, Crank Sprocket.> 7) Remove the rear chain cover. <Ref. to ME(H6DO)-53, REMOVAL, Rear Chain Cover.> 8) Remove the camshaft. <Ref. to ME(H6DO)-55, REMOVAL, Camshaft.> 9) Remove the cylinder head bolts in the numerical order as shown in the figure. Leave bolts (2) and (4) engaged by three or four threads to prevent the cylinder head from falling.
(8) (2) (6) (4)
12) Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. 13) Similarly, remove the cylinder head (RH).
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. NOTE: Use new cylinder head gaskets. 2) Tighten the cylinder head bolts. (1) Apply a thin coat of engine oil to washers and cylinder head bolt threads. (2) Mount the cylinder head onto the cylinder block, then tighten the bolts with a torque of 20 Nm (2.0 kgf-m, 14.8 ft-lb) in the order indicated in the figure. (3) Tighten the bolts with a torque of 50 Nm (5.1 kgf-m, 36.9 ft-lb) in the order indicated in the figure. (4) Loosen all the bolts by 180 in the reverse order of installing, and loosen them further by 180. (5) Tighten the bolts with a torque of 20 Nm (2.0 kgf-m, 14.8 ft-lb) in the order indicated in the figure. (6) Tighten the bolts (1) (4) in the order indicated with a torque of 48 Nm (4.9 kgf-m, 35.4 ft-lb). (7) Tighten the bolts (5) (8) in the order indicated with a torque of 44 Nm (4.5 kgf-m, 32.5 ft-lb). (8) Tighten all bolts 90 in the numerical order as shown in the figure. (9) Tighten the bolt (1) (4) by 45 in the numerical order.
(1) (7) (3) (5)
(3) (5) (7)
(1)
ME-02063
10) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. 11) Remove the bolts (2) and (4) to remove cylinder head.
(8) (2) (6) (4)
(6) (4) (3) (5) (7) (1) (2)
(8)
ME-02064
ME-02063
3) Install the camshaft. <Ref. to ME(H6DO)-56, INSTALLATION, Camshaft.> 4) Install the rear chain cover. <Ref. to ME(H6DO)53, INSTALLATION, Rear Chain Cover.>
ME(H6DO)-59
Cylinder Head
MECHANICAL
5) Install the crank sprocket. <Ref. to ME(H6DO)52, INSTALLATION, Crank Sprocket.> 6) Install the cam sprocket. <Ref. to ME(H6DO)-51, INSTALLATION, Cam Sprocket.> 7) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 8) Install the front chain cover. <Ref. to ME(H6DO)44, INSTALLATION, Front Chain Cover.> 9) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 10) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
D: ASSEMBLY
1) Installation of valve spring and valve: (1) Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE (2) Coat the stem of each valve with engine oil and insert the valve into the valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. (3) Install the valve spring and retainer. NOTE: Be sure to install the valve spring with its closecoiled end facing the seat on cylinder head. For the valve spring on intake side, install two of them (inner and outer). Install the valve spring with the painted side facing to retainer.
(1) (4)
C: DISASSEMBLY
1) Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE 2) Remove the valve lifter. 3) Set the ST on valve spring retainer. Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: Mark each valve to prevent confusion. Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. Keep all the removed parts in order for re-installing in their original positions. For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to Inspection. <Ref. to ME(H6DO)61, VALVE GUIDE, INSPECTION, Cylinder Head.> <Ref. to ME(H6DO)-63, INTAKE AND EXHAUST VALVE OIL SEAL, INSPECTION, Cylinder Head.>
(2)
(3) ME-03107
(1) (2) (3) (4)
Valve spring seat Valve spring Retainer Painted face
(4) Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER
ST ST
ME-03106 ME-03106
(5) Compress the valve spring and fit the valve spring retainer key. (6) After installing, tap the valve spring retainers lightly with a plastic hammer for better seating. 2) Apply oil to the surface of valve lifter and valve shim. 3) Install the valve lifter and valve shim.
ME(H6DO)-60
Cylinder Head
MECHANICAL
E: INSPECTION
1. CYLINDER HEAD
1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE 3) Inspect the cylinder head surface that mates with cylinder block for warping by using a straight edge (A) and thickness gauge (B). If the warping exceeds the limit, replace the cylinder head. Warping limit: 0.02 mm (0.0008 in) Standard height of cylinder head: 124r0.05 mm (4.88r0.0020 in) NOTE: Uneven torque for the cylinder head bolts can cause warping. When reinstalling, pay special attention to the torque so as to tighten evenly.
3. VALVE GUIDE
1) Check the clearance between valve guide and stem. The clearance can be checked by measuring the valve stem outer diameter with a micrometer and valve guide inner diameter with a caliper gauge respectively. Clearance between the valve guide and valve stem: Standard Intake 0.030 0.057 mm (0.0012 0.0022 in) Exhaust 0.040 0.067 mm (0.0016 0.0026 in) 2) If the clearance between valve guide and stem exceeds the standard, replace the valve guide or valve itself whichever shows greater amount of wear or damaged and etc. See the following procedure for valve guide replacement. Valve guide inner diameter: 5.500 5.512 mm (0.2165 0.2170 in) Valve stem outer diameters: Intake 5.455 5.470 mm (0.2148 0.2154 in) Exhaust 5.445 5.460 mm (0.2144 0.2150 in) (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. (2) Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499765700 VALVE GUIDE REMOVER
(A)
(B) ME-00551
2. VALVE SEAT
Inspect the intake and exhaust valve seats. Correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced. Valve seat width W: Standard Intake 1.0 mm (0.039 in) Exhaust 1.5 mm (0.059 in)
ME-00553
ME-00127
ME(H6DO)-61
Cylinder Head
MECHANICAL
(3) Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA040 VALVE GUIDE ADJUSTER

1) Inspect the flange and stem of the valve, and replace if damaged, worn, or deformed, or if H is outside of the standard. Head edge thickness H: Standard Intake (A) 1.0 mm (0.039 in) Exhaust (B) 1.2 mm (0.047 in)
ST
ME-00757
(4) Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head. (5) Put a new valve guide, coated with sufficient oil, in the cylinder head, and insert the ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499765700 VALVE GUIDE REMOVER ST2 18251AA040 VALVE GUIDE ADJUSTER
ST1 ST2
(A)
H
+1 0
90
(B)
H
+1 0 ME-02096 ME-00130
90
(6) Check the valve guide protrusion. Valve guide protrusion L: 11.4 11.8 mm (0.449 0.465 in) (7) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. ST 499765900 VALVE GUIDE REAMER NOTE: Apply engine oil to the ST when reaming. If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. (8) After reaming, clean the valve guide to remove chips. (9) Recheck the contact condition between valve and valve seat after replacing the valve guide.
2) Put a small amount of grinding compound on the seat surface, and lap the valve and valve seat. Install a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length. Valve overall length: Intake 99.7 mm (3.925 in) Exhaust 105.2 mm (4.142 in)
ME(H6DO)-62
Cylinder Head
MECHANICAL
5. VALVE SPRING
1) Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table.
Free length mm (in) Intake Exhaust Inner Intake Squareness Exhaust Outer Inner Outer 39.55 (1.5571) 41.18 (1.6213) 46.32 (1.8236) 2.5, 1.7 mm (0.067 in) or less 2.5, 1.8 mm (0.071 in) or less 2.5, 2.0 mm (0.079 in) or less
7. VALVE LIFTER
1) Check the valve lifter visually. 2) Measure the outer diameter of valve lifter. Outer diameter: 32.959 32.975 mm (1.2976 1.2982 in)
2) To measure the squareness of the valve spring, stand the valve spring on a surface plate and measure its deflection at the top of the spring using a try square.
ME-00134
3) Measure the inner diameter of valve lifter hole of cylinder head. Inner diameter: 32.994 33.016 mm (1.2990 1.2998 in)
ME-00132

1) For the following, replace the oil seal with a new part. When the lip is damaged When the spring is out of the specified position When readjusting the surfaces of valve and valve seat When replacing the valve guide 2) Set the cylinder head on ST1. 3) Using the ST2, press-fit the oil seal. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499585500 VALVE OIL SEAL GUIDE NOTE: Apply engine oil to oil seal before press-fitting. When press-fitting the oil seal, do not use a hammer to strike in.
ME-03109
NOTE: If difference between outer diameter of valve lifter and inner diameter of valve lifter hole is out of the standard or offset wearing is emitted, replace the cylinder head. Standard: 0.019 0.057 mm (0.0007 0.0022 in)
ME-03108
ME(H6DO)-63
Cylinder Block
MECHANICAL
21.Cylinder Block
A: REMOVAL
NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 2) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 3) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 4) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 5) Remove the cam sprocket. <Ref. to ME(H6DO)51, REMOVAL, Cam Sprocket.> 6) Remove the crank sprocket. <Ref. to ME(H6DO)-52, REMOVAL, Crank Sprocket.> 7) Remove the rear chain cover. <Ref. to ME(H6DO)-53, REMOVAL, Rear Chain Cover.> 8) Remove the camshaft. <Ref. to ME(H6DO)-55, REMOVAL, Camshaft.> 9) Remove the cylinder head. <Ref. to ME(H6DO)59, REMOVAL, Cylinder Head.> 10) Use the ST to lock the crankshaft, and remove the drive plate. ST1 498497100 CRANKSHAFT STOPPER ST2 499057000 TORX PLUS
12) Remove the crankshaft position sensor bracket.
ME-00559
13) Rotate the engine to set oil pan upper. 14) Remove the bolts which secure oil pan lower to oil pan upper.
ME-00560
15) Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter. 16) Remove the oil strainer.
ST ME-00557
11) Remove the crankshaft position sensor plate.
ME-00558
LU-02108
ME(H6DO)-64
Cylinder Block
MECHANICAL
17) Remove the bolts which install oil pan upper onto cylinder block. NOTE: Installation bolt has five different sizes. To prevent the confusion in installation, keep these bolts on container individually.
(B) (A) (C) (D) (E) (E) (D)
20) Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER ASSY NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
(A) (A) (A) (A) (A) (A)
(A) (B) (A) (A) (A) (A) (A) (A) (A) (A) ME-02065 ME-00565
(A) (B) (C) (D) (E)
M8 40 M8 65 M8 85 M8 130.5 M8 24
21) Similarly remove the piston pins from #3, #4, #5, and #6 pistons. 22) Remove the cylinder block connecting bolts.
18) Remove the service hole cover and service hole plugs using a hexagon wrench.
ME-00566
23) Separate the cylinder block (LH) and (RH). NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block. 24) Remove the rear oil seal. 25) Remove the crankshaft together with connecting rod. 26) Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: Be careful not to confuse the crankshaft bearing combination. Press the bearing at the end opposite to locking lip. 27) Draw out each piston from cylinder block using wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.
ME-00563
19) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then, using the ST, remove the piston snap ring through service hole of #1 and #2 cylinders. ST 18233AA000 PISTON PIN SNAP RING PLIERS
ST
ME-02603
ME(H6DO)-65
Cylinder Block
MECHANICAL
B: INSTALLATION
1) After setting the cylinder block to ST, install the crankshaft bearing. ST 18232AA000 ENGINE STAND NOTE: Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal. 2) Position the crankshaft on the cylinder block (RH). 3) Apply liquid gasket to the mating surfaces of cylinder block (RH), and position the cylinder block (LH). NOTE: Do not allow liquid gasket to run over to oil passages, bearing grooves, etc. Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 1.0r0.2 mm (0.039r0.008 in)
6) Retighten all bolts in the numerical order as shown in the figure. Tightening torque: (1) (11), (13): 25 Nm (2.5 kgf-m, 18.4 ft-lb) (12), (14): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(14) (8) (6) (1) (3) (9) (11)
(13) (12) (10) (4) (2) (5) (7) ME-00568
7) Tighten all bolts 90 110 in the numerical order as shown in the figure.
(14) (8) (6) (1) (3) (9) (11)
(13) (12) (10) (4) (2) (5) (7) ME-00568
8) Install the upper bolt to cylinder block. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) NOTE: After tightening the cylinder block connecting bolts, remove the liquid gasket which is running over to the sealing surface for rear chain cover and oil pan upper.
ME-00567
4) Apply a coat of engine oil to the washer and bolt thread. 5) Tighten all bolts in the numerical order as shown in the figure. Tightening torque: (1) (11), (13): 25 Nm (2.5 kgf-m, 18.4 ft-lb) (12), (14): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(14) (8) (6) (1) (3) (9) (11)
ME-00569
(13) (12) (10) (4) (2) (5) (7) ME-00568
ME(H6DO)-66
Cylinder Block
MECHANICAL
15) Install the snap ring. Install the snap rings in the piston holes located opposite to the service holes in cylinder block when positioning all pistons in corresponding cylinders. NOTE: Use new snap rings.
#5
#3 #6 (A) #1 #4 (B) (A) ST2 ST1 #2 ME-00573
ME-00570
(A) Front side of vehicle
(A) Rear oil seal (B) Drive plate installation bolt
10) Position the top ring gap at (A) in the figure. 11) Position the second ring gap at (B).
180
16) Installing piston: (1) Using ST1, turn the crankshaft so that #3 and #4 connecting rod small ends are set on the service hole (A). ST1 18252AA000 CRANKSHAFT SOCKET
(A)
(A)
(B)
ME-02066
(A)
ST1
ME-00574
12) Position the upper rail gap at (C) in the figure. 13) Position the expander gap at (D) in the figure. 14) Position the lower rail gap at (E) in the figure.
(E)
(2) Apply a thin coat of engine oil to piston and cylinder.
(C)
35 25
(D)
ME-02067
CAUTION: Make sure ring gaps do not face the same direction. Make sure ring gaps are not within the piston skirt area. Assemble it so that R mark faces to top side of piston.
ME(H6DO)-67
Cylinder Block
MECHANICAL
(3) Using ST2, press-fit the piston into cylinder. ST2 18254AA000 PISTON GUIDE
(3) Using ST4, install the snap ring. ST4 18233AA000 PISTON PIN SNAP RING PLIERS NOTE: Use new snap rings.
ST4
ST2 ME-00576
NOTE: Let the piston front mark (A) face towards the front of engine.
ME-00564
(4) Similarly install the #1, #2, #5 and #6 pistons. 18) Install the service hole plug and O-ring. NOTE: Use new O-rings. 19) Apply liquid gasket to the mating surface of oil pan upper.
ME-02076
(A)
NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: Full line part 3.0r1.0 mm (0.12r0.04 in) Broken line part 1.0 mm (0.04 in)
(A) (A) (A)
17) Installing piston pin: (1) Apply a coat of engine oil to ST3 before insertion, and then insert it into the service hole to align piston pin hole with connecting rod small end. ST3 18253AA000 PISTON PIN GUIDE
ST3
(A)
ME-00577
(2) Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
(A) O-ring
ME-02068
NOTE: Use new O-rings.
ME(H6DO)-68
Cylinder Block
MECHANICAL
20) Temporarily tighten the oil pan upper. NOTE: Do not install the bolts in wrong place.
(B) (A) (C) (D) (E) (E) (D)
22) Install the oil strainer. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb) NOTE: Use new O-rings.
(A) (A) (A) (A) (A) (A)
(A) (B) (A) (A) (A) (A) (A) (A) (A) (A) ME-02069
(A) (B) (C) (D) (E) *:
M8 40 M8 65 M8 85 M8 130.5 M8 24 Coating
21) Tighten the oil pan upper installing bolts in the numerical order as shown in the figure. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(19) (8) (10) (20) (22) (21) (3) (1) (24) (5) (17) (13) (11) (15) (23) (26) (9) (6) (7) (2) (4) (18) (16) (12) (14) (25) (27) ME-02070 LU-02108
23) Apply liquid gasket to the matching surface of oil pan lower. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 5.0r1.0 mm (0.20r0.04 in)
ME-00581
ME(H6DO)-69
Cylinder Block
MECHANICAL
24) Tighten the oil pan lower installing bolts in the numerical order as shown in the figure. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(2) (3) (4) (5) (6) (7) (8) (9) (1) (15) (14) (13) (12) (11) (10) ME-00582
27) Use the ST to lock the crankshaft, and install the drive plate. ST1 498497100 CRANKSHAFT STOPPER ST2 499057000 TORX PLUS Tightening torque: 81 Nm (8.3 kgf-m, 59.7 ft-lb)
25) Attach the crankshaft position sensor holder. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
ST ME-00557
ME-00559
26) Install the crankshaft sensor plate.
28) Install the cylinder head. <Ref. to ME(H6DO)59, INSTALLATION, Cylinder Head.> 29) Install the camshaft. <Ref. to ME(H6DO)-56, INSTALLATION, Camshaft.> 30) Install the rear chain cover. <Ref. to ME(H6DO)-53, INSTALLATION, Rear Chain Cover.> 31) Install the crank sprocket. <Ref. to ME(H6DO)52, INSTALLATION, Crank Sprocket.> 32) Install the cam sprocket. <Ref. to ME(H6DO)51, INSTALLATION, Cam Sprocket.> 33) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 34) Install the front chain cover. <Ref. to ME(H6DO)-44, INSTALLATION, Front Chain Cover.> 35) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 36) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.>
ME-00558
ME(H6DO)-70
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(6)
(1)
(3) (4) (5)
(7) (2) (2) (7)
(1) (5) (2) (4) (3)
(6)
ME-03955
(1) (2) (3)
(4) (5)
(6) (7)
1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order, to prevent confusion. 3) Remove the piston rings using piston ring expander. 4) Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order, to prevent confusion. 5) Remove the snap ring.
ME(H6DO)-71
Cylinder Block
MECHANICAL
D: ASSEMBLY
(6)
(1)
(3) (4) (5)
(7) (2) (2) (7) (2) (1) (5) (4) (3)
(6)
ME-02459
(1) (2) (3) (4)
Connecting rod cap Connecting rod bearing Top ring Second ring
(5) (6) (7)
Oil ring Snap ring Connecting rod
1) Apply oil to the surface of the connecting rod bearings, and install the bearings on the connecting rods and connecting rod caps. 2) Position each connecting rod with the marking side facing forward. 3) Install the connecting rod cap. Make sure the arrow mark on connecting rod cap facing front during installation. CAUTION: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod bolts, apply oil on the threads and flange end. Tightening torque: 53 Nm (5.4 kgf-m, 39.1 ft-lb) 4) Install the oil ring spacer, upper rail and lower rail by hand. 5) Install the second ring and top ring using piston ring expander.
ME(H6DO)-72
Cylinder Block
MECHANICAL
E: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Check the oil passages for clogging. 3) Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge. If the warping exceeds the limit, replace the cylinder block. Warping limit: 0.02 mm (0.0008 in) Standard height of cylinder block: 202 mm (7.95 in)
2) How to measure the inner diameter of each cylinder: Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20C (68F). Cylindricality: Standard 0.030 mm (0.0012 in) Out-of-roundness: Standard 0.010 mm (0.0004 in)
(A) (B)

H1
H2 H3
Unit: mm (in)
ME-00586
(A) (B) H1: H2: H3:

(A) #7 #6 #5 #4 #3 #2 #1 #6 #4 #5 #2 #3 #1 (B) 2 4 2 4
Piston pin direction Thrust direction 10 mm (0.39 in) 45 mm (1.77 in) 80 mm (3.15 in)
3) When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
(A) Main journal size mark (B) Cylinder bore size mark (C) Cylinder block (RH) (LH) combination mark
B B B
B A B
(C) ME-00585
ME(H6DO)-73
Cylinder Block
MECHANICAL
4) How to measure the outer diameter of each piston: Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20C (68F). Piston grade point H: 37.3 mm (1.4685 in) Piston outer diameter: Standard A: 89.205 89.215 mm (3.5120 3.5124 in) B: 89.195 89.205 mm (3.5116 3.5120 in) 0.25 mm (0.0098 in) oversize 89.445 89.465 mm (3.5215 3.5222 in) 0.50 mm (0.0197 in) oversize 89.695 89.715 mm (3.5313 3.5321 in)
(2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. Cylinder inner diameter boring limit (diameter): To 89.715 mm (3.5321 in) NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter.

1) Check the piston and piston pin for breaks, cracks or wear. Replace if faulty. 2) Check the piston ring groove for wear or damage. Replace if faulty. 3) Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20C (68F). Replace if faulty. Standard clearance between piston pin and hole in piston: Standard 0.004 0.008 mm (0.0002 0.0003 in)
H ME-00172
5) Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20C (68F). Cylinder to piston clearance at 20C (68F): Standard 0.010 0.010 mm (0.0004 0.0004 in) 6) Boring and honing: (1) If the value of cylindrically, out-of-roundness, or cylinder-to-piston clearance measured is out of standard or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, other cylinders must be bored at the same time, and replaced with oversize pistons. Do not perform boring on one cylinder only. Do not replace only a single cylinder for an oversize piston.
ME-00174
ME-00173
ME(H6DO)-74
Cylinder Block
MECHANICAL
2) Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
Standard mm (in) 0.20 0.35 (0.0079 0.0138) 0.35 0.50 (0.0138 0.0197) 0.20 0.60 (0.0079 0.0236)
Top ring
(A)
Piston ring gap
ME-00175
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: The top ring and second ring have the mark to determine the direction to install on them. When installing the ring to piston, face this mark to the top side. Oil ring consists of the upper rail, expander and lower rail. When installing on the piston, be careful of the direction of each rail.
(A) ME-00592
Standard mm (in) 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028) 0.045 0.125 (0.0018 0.0049)
(B) (a) (b) (C) (c) ME-00591
Clearance between oil ring and oil ring groove
(A) (B) (C) (a) (b) (c)
Top ring Second ring Oil ring Upper rail Expander Lower rail
ME-00178
ME(H6DO)-75
Cylinder Block
MECHANICAL
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace the connecting rod if it has the bend or twist.
(A)
5) Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.016 0.043 mm (0.0006 0.0017 in)
Bearing Standard 0.03 (0.0012) undersize 0.05 (0.0020) undersize 0.25 (0.0098) undersize Bearing size (Thickness at center) 1.490 1.506 (0.0587 0.0593) 1.509 1.513 (0.0594 0.0596) 1.519 1.523 (0.0598 0.0600) 1.619 1.623 (0.0637 0.0639) Unit: mm (in) Outer diameter of crank pin 51.984 52.000 (2.0466 2.0472) 51.954 51.970 (2.0454 2.0461) 51.934 51.950 (2.0446 2.0453) 51.734 51.750 (2.0368 2.0374)
(B)
(A)
(B)
ME-00179
6) Inspect the bushing at connecting rod small end, and replace if worn or damaged. 7) Measure the piston pin clearance at connecting rod small end. If the measured value is not within the standard, replace it with a new part. Clearance between piston pin and bushing: Standard 0 0.022 mm (0 0.0009 in)
3) Install the connecting rod fitted with bearing to crankshaft and measure the thrust clearance. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod. Connecting rod thrust clearance: Standard 0.070 0.330 mm (0.0028 0.0130 in)
ME-00181
ME-00180
ME-00174
ME(H6DO)-76
Cylinder Block
MECHANICAL
8) The replacement procedure for the connecting rod small end bushing is as follows. (1) Remove the bushing from connecting rod with ST and press. (2) Press the bushing with ST after applying oil on the periphery of bushing. ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER

1) Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. Replace if defective. 2) Check the crankshaft for bend, and repair or replace if needed. Repair or replace if bended. NOTE: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings, and then check the crankshaft bend using a dial gauge.
ST
ME-00597
(3) Make two 3 mm (0.12 in) holes in the pressed bushing by aligning with the pre-manufactured holes on the connecting rod, and ream the inside of the bushing. (4) After completion of reaming, clean the bushing to remove chips.
ME-00598
3) Inspect the crank journal and crank pin for wear. If they are not within the specification, replace the bearing with a suitable (undersize) one, and replace or readjust crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin and crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in)
ME-00184
ME(H6DO)-77
Cylinder Block
MECHANICAL
Unit: mm (in) Crank journal diameter #1, #3, #5, #7 #2, #4, #6 63.992 64.008 (2.5194 2.5200) 1.992 2.005 1.996 2.009 (0.0784 0.0789) (0.0786 0.0791) 63.962 63.978 (2.5182 2.5188) 2.011 2.014 2.015 2.018 (0.0792 0.0793) (0.0793 0.0794) 63.942 63.958 (2.5174 2.5180) 2.021 2.024 2.025 2.028 (0.0796 0.0797) (0.0797 0.0798) 63.742 63.758 (2.5095 2.5102) 2.121 2.124 2.125 2.128 (0.0835 0.0836) (0.0837 0.0838) Crank pin outer diameter 51.984 52.000 (2.0466 2.0472) 1.490 1.506 (0.0587 0.0593) 51.954 51.970 (2.0454 2.0461) 1.509 1.513 (0.0594 0.0596) 51.934 51.950 (2.0446 2.0453) 1.519 1.523 (0.0598 0.0600) 51.734 51.750 (2.0368 2.0374) 1.619 1.623 (0.0637 0.0639)
0.03 (0.0012) undersize
0.05 (0.0020) undersize
0.25 (0.0098) undersize
4) Measure the thrust clearance of crankshaft at center bearing by using thickness gauge. If the thrust clearance is not within the standard, replace the bearing. Crankshaft thrust clearance: Standard 0.030 0.115 mm (0.0012 0.0045 in)
ME-00600
5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear. 6) Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 0.030 mm (0.0004 0.0012 in)
ME(H6DO)-78
Oil Flow Control Solenoid Valve

MECHANICAL
22.Oil Flow Control Solenoid Valve

A: REMOVAL
Oil flow control solenoid valve is a unit with camshaft cap. Refer to Camshaft for removal procedures. <Ref. to ME(H6DO)-55, REMOVAL, Camshaft.>
B: INSTALLATION
ME(H6DO)-79

MECHANICAL
23.Oil Switching Solenoid Valve

A: REMOVAL
B: INSTALLATION
1) Install the oil switching solenoid valve holder. NOTE: Use a new gasket. (1) Temporarily tighten the bolts by tightening torque of 5 10 Nm (0.5 1.0 kgf-m, 3.7 7.4 ft-lb) in order shown in the figure. (2) Tighten the bolts by tightening torque of 10r0.5 Nm (1.0r0.05 kgf-m, 7.4r0.37 ft-lb) in order shown in the figure.
(5)
IN-00203
(2)
(1)
2) Remove the air intake chamber. <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 3) Disconnect the connector from the oil switching solenoid valve.
(3) (4)
ME-02073
ME-02071
4) Remove the oil switching solenoid valve. 5) Remove the variable valve lift diagnosis oil pressure switch. <Ref. to FU(H6DO)-30, REMOVAL, Variable Valve Lift Diagnosis Oil Pressure Switch.> 6) Remove the oil temperature sensor. <Ref. to FU(H6DO)-31, REMOVAL, Oil Temperature Sensor.> 7) Remove the oil switching solenoid valve holder from the cylinder head.
2) Install the oil temperature sensor. <Ref. to FU(H6DO)-31, INSTALLATION, Oil Temperature Sensor.> 3) Install the variable valve lift diagnosis oil pressure switch. <Ref. to FU(H6DO)-30, INSTALLATION, Variable Valve Lift Diagnosis Oil Pressure Switch.> 4) Install the oil switching solenoid valve. 5) Connect the connector to the oil switching solenoid valve.
ME-02071
6) Install the air intake chamber. <Ref. to IN(H6DO)7, INSTALLATION, Air Intake Chamber.> 7) Connect the ground cable to battery.
ME-02072
IN-00203
ME(H6DO)-80

MECHANICAL

A: SPECIFICATION
Refer to Cylinder Head for removal and installation procedures of the intake and exhaust valves. <Ref. to ME(H6DO)-59, REMOVAL, Cylinder Head.> <Ref. to ME(H6DO)-59, INSTALLATION, Cylinder Head.>
ME(H6DO)-81
Piston
MECHANICAL
25.Piston
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of pistons. <Ref. to ME(H6DO)-64, REMOVAL, Cylinder Block.> <Ref. to ME(H6DO)66, INSTALLATION, Cylinder Block.>
ME(H6DO)-82
Connecting Rod
MECHANICAL
26.Connecting Rod
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of connecting rods. <Ref. to ME(H6DO)-64, REMOVAL, Cylinder Block.> <Ref. to ME(H6DO)-66, INSTALLATION, Cylinder Block.>
ME(H6DO)-83
Crankshaft
MECHANICAL
27.Crankshaft
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of the crankshaft. <Ref. to ME(H6DO)-64, REMOVAL, Cylinder Block.> <Ref. to ME(H6DO)-66, INSTALLATION, Cylinder Block.>
ME(H6DO)-84

MECHANICAL

A: INSPECTION
Symptoms 1. Engine does not start. 1) Starter does not turn. Problem parts etc. Starter Possible cause RANK B C C B A A B C C C C A A C B B B C C C C C B C B B C B
Defective battery-to-starter harness Defective starter switch Defective inhibitor switch Defective starter Battery Improper connection of the terminal Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Starter Defective starter Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing chain Trouble Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Trouble of valve lifter Trouble of valve lifter. In case noise occurs with valve moving, or when the harness involved to the oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.
ME(H6DO)-85

MECHANICAL
Symptoms 3) Initial combustion occurs. Problem parts etc. Possible cause Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing chain Trouble Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of or insufficient fuel Timing chain Trouble Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) RANK A B B C C B B B C C C C C B C B B C B
A B C C B B C C B B B C C C C C B C B B C B
ME(H6DO)-86

MECHANICAL
Symptoms 2. Rough idle and engine stall Problem parts etc. Possible cause RANK A A A A B B C B C C C B C B B B B C B B A B C B
Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Over-heating Others Evaporative emission control system malfunction Stuck or damaged throttle valve
B C C A B
ME(H6DO)-87

MECHANICAL
Symptoms 3. Low output, hesitation and poor acceleration Problem parts etc. Possible cause RANK A A A B B B B B A B B C B B B B B C B C A B C B
Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) Lubrication system Incorrect oil pressure Cooling system Over-heating Over-cooling Others Evaporative emission control system malfunction
B C C A
ME(H6DO)-88

MECHANICAL
Symptoms 4. Surging Problem parts etc. Possible cause RANK A A A A B B B B B B B C B B C C C C C C A B C B
5. Engine does not return to idle. 6. Dieseling (Run-on)
Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Cooling system Over-heating Others Evaporative emission control system malfunction
B C A A A A B B
ME(H6DO)-89

MECHANICAL
Symptoms 7. After burning in exhaust system Problem parts etc. Possible cause Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) Lubrication system Incorrect oil pressure Cooling system Over-cooling Others Evaporative emission control system malfunction Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> Intake system Loosened oil filler cap Timing chain Defective timing Compression Incorrect valve clearance Incorrect valve timing Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) Cooling system Over-heating Intake system Loosened or cracked PCV hose Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter O-ring Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan RANK A C C B B C B B C C B C C C A C B
8. Knocking
C C C A B B C B C B
A A B C A A B B B B B B
ME(H6DO)-90

MECHANICAL
Symptoms Problem parts etc. Possible cause 10. Excessive fuel consump- Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.> tion Intake system Dirty air cleaner element Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Trouble of valve lifter Trouble of valve lifter. (In case noise occurs with valve moving. Or the harness involved to oil switching solenoid valve, variable valve lift diagnosis oil pressure switch and variable valve lift has trouble in a past.) Lubrication system Incorrect oil pressure Cooling system Over-cooling RANK A A B B C C B C C B B C B
C C
ME(H6DO)-91
Engine Noise
MECHANICAL
29.Engine Noise
A: INSPECTION
Possible cause Valve mechanism is defective. Incorrect valve clearance Sound increases as engine Worn camshaft Regular clicking sound speed increases. Broken valve spring Trouble of valve lifter Worn crankshaft main bearing Oil pressure is low. Worn connecting rod bearing (large end) Heavy and dull clank Oil pressure is normal. Damaged engine mounting Ignition timing advanced Sound is noticeable when Accumulation of carbon inside combustion chamber High-pitched clank accelerating with an overload Wrong heat range of spark plug condition. Improper octane value of gasoline Noise is reduced when fuel Worn crankshaft main bearing Clank when engine speed is injector connector of noisy cyl- Worn connecting rod bearing (large end) between 1,000 and 2,000 rpm. inder is disconnected. (NOTE*) Noise is reduced when fuel injector connector of noisy cylinder is disconnected. (NOTE*) Sound is not reduced if each fuel injector connector is disconnected in turn. (NOTE*) Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Unusually worn valve lifter Worn cam gear Worn camshaft journal bore in cylinder head Insufficient generator lubrication Poor contact of generator brush and rotor Defective ignition starter switch Worn gear and starter pinion Loose drive belt Defective water pump shaft Insufficient compression Air leakage in air intake system, hose, connection or manifold Loose timing chain Timing chain contacting with adjacent part Incorrect valve clearance Trouble of valve lifter Type of sound Condition
Squeaky sound Rubbing sound Gear scream when starting engine Sound like polishing glass with a dry cloth Hissing sound Timing chain noise Valve noise
NOTE*) When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H6DO)-92
General Description
EXHAUST
A: COMPONENT
(24)
(16)
(24) (26) (24) T6 (25) (21) (20) (23) (22) (24) (25) T6
(17)
(26) (24)
(19) T4 (18)
(1)
T5 T2 (8) T3 (14) (15) T3
T1 (3) T3 (5) (4) (7)
(2)
(12) (13) (9) (10)
(6) T3 T4 T1 T4 (11)
EX-02374
EX(H6DO)-2
General Description
EXHAUST
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Front catalytic converter upper cover (RH) Front catalytic converter lower cover (RH) Gasket Front exhaust pipe (RH) Front catalytic converter (RH) Front oxygen (A/F) sensor (RH) Rear oxygen sensor (RH) Gasket Gasket Front catalytic converter upper cover (LH) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) Front catalytic converter lower cover (LH) Front exhaust pipe (LH) Front catalytic converter (LH) Front oxygen (A/F) sensor (LH) Rear oxygen sensor (LH) Muffler (RH) Muffler (LH) Rear catalytic converter Bracket Gasket Spring Chamber (23) (24) (25) (26) Rear exhaust pipe Cushion rubber Self-locking nut Gasket
Tightening torque:Nm (kgf-m, ft-lb) T1: 13 (1.3, 9.6) T2: 18 (1.8, 13.3) T3: 21 (2.1, 15.5) T4: 30 (3.1, 22.1) T5: 35 (3.6, 25.8) T6: 48 (4.9, 35.4)
B: CAUTION
EX(H6DO)-3
Front Exhaust Pipe

EXHAUST

A: REMOVAL
7) Remove the nuts which hold front exhaust pipe assembly onto cylinder heads. CAUTION: Be careful not to drop the front exhaust pipe assembly.
EX-02016
8) Remove the bolts which hold front exhaust pipe assembly to hanger bracket.
IN-00203
3) Lift up the vehicle. 4) Remove the under cover. 5) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
(A)
EX-00061
(B)
9) Remove the front exhaust pipe assembly from vehicle. CAUTION: Be careful not to let the front exhaust pipe assembly fall off when removing, since it is very heavy. After removing the front exhaust pipe assembly, do not apply excessive pulling force on the rear exhaust pipe. 10) Separate the front exhaust pipe (RH) from front exhaust pipe assembly.
EX-02014
6) Separate the front exhaust pipe assembly from the rear exhaust pipe.
EX-02015
EX-02017
11) Remove the front oxygen (A/F) sensor and rear oxygen sensor. <Ref. to FU(H6DO)-32, REMOVAL, Front Oxygen (A/F) Sensor.> <Ref. to FU(H6DO)-34, REMOVAL, Rear Oxygen Sensor.>
EX(H6DO)-4
Front Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear oxygen sensor. <Ref. to FU(H6DO)-33, INSTALLATION, Front Oxygen (A/F) Sensor.> <Ref. to FU(H6DO)-35, INSTALLATION, Rear Oxygen Sensor.> 2) Install the front exhaust pipe (RH) to the front exhaust pipe (LH). NOTE: Use a new gasket. Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft-lb)
6) Tighten the bolts which install front exhaust pipe to rear exhaust pipe. NOTE: Use a new gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-02015
7) Tighten the bolts which hold front exhaust pipe assembly to hanger bracket. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
EX-02017
3) Install the front exhaust pipe assembly to vehicle. 4) Temporarily tighten the nuts which hold front exhaust pipe assembly onto cylinder heads. NOTE: Use a new gasket.
EX-00061
8) Tighten the nuts which hold front exhaust pipe to cylinder heads. Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft-lb)
EX-02016
5) Temporarily tighten the bolts which hold front exhaust pipe assembly to hanger bracket.
EX-02016
9) Install the under cover.
EX-00061
EX(H6DO)-5
Front Exhaust Pipe

EXHAUST
10) Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
(A)
(B)
EX-02014
IN-00203
C: INSPECTION
EX(H6DO)-6
Rear Exhaust Pipe

EXHAUST

A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Separate the rear exhaust pipe from front exhaust pipe assembly.
EX-00219
EX-02015
EX-00222
RH side
EX-00218
EX(H6DO)-7
Rear Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Apply a coat of spray type lubricant to the mating area of cushion rubber. 2) Install the rear exhaust pipe bracket to cushion rubber. NOTE: After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.
4) Install the rear exhaust pipe assembly to center exhaust pipe. NOTE: Use a new gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
EX-02015

EX-00219
C: INSPECTION
3) Install the rear exhaust pipe to muffler. NOTE: Use a new gasket and self-locking nut. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb) LH side
EX-00222
RH side
EX-00218
EX(H6DO)-8
Muffler
EXHAUST
4. Muffler
A: REMOVAL
CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Separate the muffler from rear exhaust pipe. LH side
RH side
EX-00221
B: INSTALLATION
EX-00222
RH side
EX-00218
EX-00222
4) Apply a coat of spray type lubricant to the mating area of cushion rubber. 5) Remove the front and rear cushion rubber, and then remove the muffler. CAUTION: Be careful not to drop the muffler during removal. LH side
RH side
EX-00218
C: INSPECTION
EX-00220
EX(H6DO)-9
Muffler
EXHAUST
EX(H6DO)-10
General Description
COOLING
A: SPECIFICATION
Cooling system Total engine coolant capacity Type Discharge performance I 2 (US qt, Imp qt) Electric fan + Forced engine coolant circulation system Approx. 7.2 (7.6, 6.3) Centrifugal impeller type 320 (84.5, 70.4) 5,500 rpm 176.5 kPa (18 mAq) 80C (176F) 73.2 (2.88) 6 22 Wax pellet type 80 84C (176 183F) 95C (203F) 9.0 (0.354) or more 35 (1.38) 160 160 320 mm (12.6 in)/5 320 mm (12.6 in)/7 Down flow, pressure type 690 349 16 (27.17 13.74 0.63)
Water pump
Thermostat
Radiator fan
Discharge rate 2 (US gal, Imp gal)/min. Pump speed Discharge pressure Engine coolant temperature Impeller diameter mm (in) Number of impeller vanes Number of pump sprocket teeth Type Starting temperature to open Fully opens Valve lift mm (in) Valve bore mm (in) Main fan W Motor input Sub fan W Main fan Fan diameter / Blade Sub fan Type Core dimensions Width Height Thickness mm (in) kPa (kgf/cm2, psi)
Radiator
Pressure range in which cap valve is open Fins Reservoir tank Capacity
Above: 108r14.7 (1.1r0.15, 16r2) Below: The atmospheric pressure or less Corrugated fin type 2 (US qt, Imp qt) 0.45 (0.48, 0.40) Item number K0670Y0000 SOA345001 Alternative Soft water or tap water
Coolant Water for dilution Cooling system protective agent
Recommended materials SUBARU SUPER COOLANT (Concentrated type) SUBARU SUPER COOLANT (Diluted type) Distilled water Cooling system conditioner
A/C compressor
A/C middle pressure switch
OFF ON OFF ON
Engine coolant temperature Increase: 102C (216F) Increase: less than 95C Increase: 95 101C (203F) (203 214F) or more Decrease: less than 93C Decrease: 93 99C Decrease: 100C (212F) (199F) (199 210F) or more 0% Refer to fig. (1) 100% Refer to fig. (2) 100% Refer to fig. (3) 100%
CO(H6DO)-2
General Description
COOLING
(1) (A) (A)
(2) (A)
(3)
100 70 70 70
(B)
(B)
(B)
CO-02115
(A) (1)
Fan speed (%) A/C OFF control
(B) (2)
Water temperature A/C ON control (A/C middle pressure switch OFF) (3) A/C ON control (A/C middle pressure switch ON)
CO(H6DO)-3
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(4)
(3) (5)
(2)
(1)
CO-02291
(1) (2) (3)
Water pump ASSY O-ring Thermostat
(4) (5)
Gasket Thermostat cover
Tightening torque:Nm (kgf-m, ft-lb) T: 6.4 (0.7, 4.7)
CO(H6DO)-4
General Description
COOLING
2. RADIATOR AND RADIATOR FAN

(27) T4 (14) (13) (19) (12) T4 (16) (18) T5 (5) T4 (7) (8) (6) (4) (7) T3 T3 (20) (23) (7) (9) (11) (15) T4 T4 (21) (9) (2) (21) (26) (21) (21) (1) (21) (21) (24) T1 (17) (21) (22) T1 T2
(3) (7)
(10)
(25) CO-02508
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Radiator lower bracket Radiator lower cushion Engine coolant drain cock Radiator Radiator upper bracket Radiator upper cushion Clip Radiator inlet hose A Clip Radiator inlet hose B Radiator outlet hose Radiator sub fan
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)
Radiator sub fan motor Radiator sub fan shroud Radiator main fan Radiator main fan motor Radiator main fan shroud Engine coolant reservoir tank cap Over flow hose Engine coolant reservoir tank ATF hose clamp ATF hose A ATF hose B
(24) (25) (26) (27)
ATF pipe ATF hose C ATF hose D Radiator fan control unit
Tightening torque:Nm (kgf-m, ft-lb) T1: 3.8 (0.4, 2.8) T2: 5.4 (0.6, 4.0) T3: 6.2 (0.6, 4.6) T4: 7.5 (0.8, 5.5) T5: 12 (1.2, 8.9)
CO(H6DO)-5
General Description
COOLING
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 499977100 DESCRIPTION CRANK PULLEY WRENCH REMARKS Used for stopping rotation of crank pulley when loosening and tightening crank pulley bolts.
ST-499977100
1B022XU0
ST1B022XU0
2. GENERAL TOOL
CO(H6DO)-6
Radiator Fan System

COOLING

A: WIRING DIAGRAM
MAIN SBF SBF-6
No.2
MAIN FUSE BOX (M/B) MAIN FAN RELAY 1 B: B143 E: F36
E6
B7
THROUGH JOINT CONNECTOR 16 F108 7 B361
RADIATOR FAN CONTROL UNIT F106 1 F17 2
18
29
B136
M
MAIN FAN MOTOR
M
SUB FAN MOTOR ECM
F106 1 2 3
B361 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B: B143 3 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
F108 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 F17 1 2
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
E:
F36
1 2 4 5
CO-02254
CO(H6DO)-7
Radiator Fan System

COOLING
B: RADIATOR FAN CONTROL OUTPUT WAVEFORM
(V)
(A)
CO-02117
(A)
5V
C: INSPECTION
DETECTING CONDITION: Engine coolant temperature is 93C (199F) or more. A/C switch is turned OFF. Vehicle speed is 19 km/h (12 MPH) or less. TROUBLE SYMPTOMS: Radiator main and sub fans do not rotate under the above conditions.
1 Step CHECK MAIN FAN RELAY 1. 1) Turn the ignition switch to OFF. 2) Remove main fan relay 1 from the main fuse box. 3) Measure the resistance of terminal in main fan relay 1 switch. CHECK MAIN FAN RELAY 1. 1) Connect the main fan relay 1 coil side terminal to the battery. 2) Measure the resistance between terminals of main fan relay 1 switch. CHECK POWER SUPPLY FOR ECM. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 29 (+) Chassis ground (): Check Is the resistance 1 M: or more? Yes Go to step 2. No Replace the main fan relay 1.
Go to step 4.
CO(H6DO)-8
Radiator Fan System

COOLING
Step CHECK POWER SUPPLY FOR RADIATOR FAN CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Connect the connector to ECM. 3) Disconnect the connector from radiator fan control unit. 4) Turn the ignition switch to ON. 5) Measure the voltage between radiator fan control unit connector and chassis ground. Connector & terminal (F106) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND RADIATOR FAN CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between radiator fan control unit and ECM connector. Connector & terminal (B136) No. 18 (F106) No. 2: CHECK RADIATOR FAN CONTROL UNIT AND GROUND CIRCUIT. 1) Connect the connector to ECM and radiator fan control unit. 2) Measure the resistance between radiator fan control unit connector and chassis ground. Connector & terminal (F106) No. 3 Chassis ground: CHECK FAN MOTOR. 1) Disconnect the connector from radiator fan control unit. 2) Connect the battery positive (+) terminal to terminal No. 1 of the radiator fan control unit, and the ground () terminal to terminal No. 3. CHECK OUTPUT SIGNAL FROM ECM. 1) Connect the delivery (test) mode connector. 2) Turn the ignition switch to ON. 3) Check the output waveform using oscilloscope. <Ref. to CO(H6DO)-8, RADIATOR FAN CONTROL OUTPUT WAVEFORM, Radiator Fan System.> Connector & terminal (B136) No. 18 (+) Chassis ground (): Check Is the voltage 10 V or more? Yes Go to step 5. No Repair the power supply line.
Repair the open circuit of harness between ECM and radiator fan control unit.
Repair the open circuit of harness between radiator fan control unit connector and chassis ground.
Does the fan motor rotate?
Go to step 8.
Replace the fan motor which does not rotate.
Is a waveform output?
Replace the radiator fan control unit. <Ref. to CO(H6DO)-25, Radiator Fan Control Unit.>
Replace the ECM. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
CO(H6DO)-9
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Remove the drain plug to drain engine coolant into container. NOTE: Remove the radiator cap so that engine coolant will drain faster.
3) Fill engine coolant into the reservoir tank up to FULL level.
(1) (2)
CO-00110
(1) FULL (2) LOW
CO-02012

1) Pour cooling system conditioner through the filler neck. Cooling system protective agent: Refer to SPECIFICATION for the cooling system protective agent. <Ref. to CO(H6DO)2, SPECIFICATION, General Description.> 2) Pour engine coolant into the radiator up to the filler neck position. Recommended engine coolant: Refer to SPECIFICATION for the recommended engine coolant. <Ref. to CO(H6DO)2, SPECIFICATION, General Description.> Amount of engine coolant: Refer to SPECIFICATION for the amount of engine coolant. <Ref. to CO(H6DO)-2, SPECIFICATION, General Description.> Engine coolant concentration: Refer to ADJUSTMENT for the engine coolant concentration. <Ref. to CO(H6DO)-11, ADJUSTMENT, Engine Coolant.> NOTE: The SUBARU Super Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum cylinder block. Always use SUBARU Super Coolant since other coolants may cause corrosion.
4) Close the radiator cap and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.) 5) Wait for one minute after the engine stops, and open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position. 6) Perform the procedures 4) and 5) again. 7) Attach the radiator cap and reservoir tank cap properly. 8) Start the engine and operate the heater at maximum hot position and the blower speed setting to LO. 9) Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: Be careful with the engine coolant temperature gauge to prevent overheating. 10) Stop the engine and wait until the engine coolant temperature lowers to 30C (86F) or less. 11) Open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position and reservoir tank to the FULL level. 12) Attach the radiator cap and reservoir tank cap properly. 13) Set the heater setting to maximum hot position and the blower speed setting to LO and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step 9).
CO(H6DO)-10
Engine Coolant
COOLING
B: ADJUSTMENT
CAUTION: Use the SUBARU Super Coolant with a 50 60% concentration in order to obtain maximum antifreeze and anti-rust performance. To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper SUBARU Super Coolant concentration in the table, and add diluting water to the SUBARU Super Coolant (concentrated type) until it reaches the proper dilution.
Relationship of Subaru Super Coolant concentration and freezing temperature SUBARU Super Coolant concentration 50% 55% Freezing temperature 36C (33F) 41C (42F) 60% 50C (58F)
Engine coolant and diluting water: Refer to SPECIFICATION for the recommended engine coolant and diluting water. <Ref. to CO(H6DO)-2, SPECIFICATION, General Description.>
CO(H6DO)-11
Water Pump
COOLING
4. Water Pump
A: REMOVAL
1) Remove the radiator. <Ref. to CO(H6DO)-15, REMOVAL, Radiator.> 2) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 3) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.> 4) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 5) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 6) Remove the water pump. NOTE: When the water pump cannot be removed easily, screw-in the bolt (A) to the threaded end to remove water pump.
B: INSTALLATION
1) Install the water pump to rear chain cover. NOTE: Use new O-rings. Apply engine coolant to O-ring. Tightening torque 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
CO-02014
(A)
(A) CO-02013
2) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 3) Install the front chain cover. <Ref. to ME(H6DO)44, INSTALLATION, Front Chain Cover.> 4) Install the crank pulley. <Ref. to ME(H6DO)-43, INSTALLATION, Crank Pulley.> 5) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.> 6) Install the radiator. <Ref. to CO(H6DO)-16, INSTALLATION, Radiator.> 7) Fill engine coolant. <Ref. to CO(H6DO)-10, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
C: INSPECTION
1) Check the water pump bearing for smooth rotation. 2) Check the water pump sprocket for abnormalities.
CO(H6DO)-12
Thermostat
COOLING
5. Thermostat
A: REMOVAL
1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine coolant completely. <Ref. to CO(H6DO)-10, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 5) Disconnect the radiator outlet hose from thermostat cover.
B: INSTALLATION
1) Install a gasket to thermostat. NOTE: Use a new gasket. 2) Install the thermostat and thermostat cover. NOTE: The jiggle pin must face upward when installing. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(D)
(C) (B) (A) CO-02015 T CO-02165
6) Remove the thermostat cover, and then remove the thermostat.
(A) (B) (C) (D)
Thermostat cover Thermostat Gasket Jiggle pin
(B) (A) CO-02164
3) Connect the radiator outlet hose to thermostat cover. 4) Install the under cover. 5) Lower the vehicle. 6) Fill engine coolant. <Ref. to CO(H6DO)-10, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
(A) Thermostat cover (B) Thermostat
CO(H6DO)-13
Thermostat
COOLING
C: INSPECTION
Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results. Inspection method Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for even temperature distribution. The measured value should meet the specification. NOTE: Leave the thermostat in the boiling water for five minutes or more before measuring the valve lift. Hold the thermostat with a wire or the like to avoid contacting with container bottom. Starting temperature to open: 80 84C (176 183F) Fully opens: 95C (203F) Valve lift: 9.0 mm (0.354 in) or more
(A)
(B)
CO-02420
CO(H6DO)-14
Radiator
COOLING
6. Radiator
A: REMOVAL
CAUTION: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Set the vehicle on a lift. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.
CO-02017
11) Remove the air intake duct. <Ref. to IN(H6DO)8, REMOVAL, Air Intake Duct.> 12) Disconnect the connector from radiator fan control unit.
IN-00203
4) Lift up the vehicle. 5) Remove the under cover. 6) Drain engine coolant completely. <Ref. to CO(H6DO)-10, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 7) Disconnect the radiator outlet hose from radiator.
CO-02018
13) Remove the reservoir tank. <Ref. to CO(H6DO)-24, REMOVAL, Reservoir Tank.> 14) Disconnect the radiator inlet hose from radiator. 15) Remove the radiator upper brackets.
(A)
CO-02015
8) Disconnect the ATF hose from the radiator.

(B)
CO-02019
(A) Radiator inlet hose (B) Radiator upper bracket
16) Lift the radiator up and away from vehicle.

CO-00253
CO(H6DO)-15
Radiator
COOLING
B: INSTALLATION
1) Attach the radiator lower cushions to holes on the vehicle.
8) Install the hood stay holder. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
CO-00126
CO-02017
2) Install the radiator to vehicle. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side. 3) Install the radiator upper brackets and tighten the bolts. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb) 4) Connect the radiator inlet hose.
(A)
9) Lift up the vehicle. 10) Connect the ATF hoses.
CO-00253
(B)
CO-02019
(A) Radiator inlet hose (B) Radiator upper bracket
5) Install the reservoir tank. <Ref. to CO(H6DO)24, INSTALLATION, Reservoir Tank.> 6) Connect the connector to the radiator fan control unit.
CO-02015
CO-02018
IN-00203
7) Install the air intake duct. <Ref. to IN(H6DO)-8, INSTALLATION, Air Intake Duct.>
15) Fill engine coolant. <Ref. to CO(H6DO)-10, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO(H6DO)-16
Radiator
COOLING
16) Check the ATF level. <Ref. to 5AT-28, INSPECTION, Automatic Transmission Fluid.> 17) Install the collector cover.
C: INSPECTION
1) Remove the radiator cap, fill the radiator with engine coolant, and then install the tester to the installation position of cap.
CO-00127
2) Apply a pressure of 157 kPa (1.6 kgf/cm2, 23 psi) to the radiator and check the following points: Leakage from the radiator or its vicinity Leakage from the hose or its connections CAUTION: Engine should be turned off. Wipe engine coolant from check points in advance. Be careful of the spurt of engine coolant when removing the tester. Be careful not to deform the filler neck of radiator when installing and removing the tester.
CO(H6DO)-17
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
CO-00044
2) Increase pressure until the tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Replace the cap if it is opened under a pressure less than the service limit value. Specification: 93 123 kPa (0.95 1.25 kgf/cm2, 14 18 psi) Service limit: 83 kPa (0.85 kgf/cm2, 12 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.
CO(H6DO)-18

COOLING

A: REMOVAL
13) Remove the reservoir tank. <Ref. to CO(H6DO)-24, REMOVAL, Reservoir Tank.> 14) Disconnect the radiator inlet hose from radiator.
CO-02020
15) Remove the radiator sub fan motor assembly.

IN-00203
CO-00129
16) Remove the radiator main fan motor assembly.

CO-02017
NOTE: When removing the main fan assembly with lifting it up, the main fan shroud contacts to inlet part of engine coolant. To avoid contacting it, move the main fan assembly to sub fan assembly side before removal.
CO-02029
CO-00130
7) Lift up the vehicle. 8) Remove the under cover. 9) Drain engine coolant completely. <Ref. to CO(H6DO)-10, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 10) Remove the ATF hose from the clip of the radiator main fan shroud. 11) Remove the radiator main fan motor harness from the clip. 12) Lower the vehicle.
CO(H6DO)-19

COOLING
B: INSTALLATION
Install in the reverse order of removal. Radiator main fan assembly Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
C: DISASSEMBLY
1) Remove the nut which holds fan to fan motor and shroud assembly.
CO-00132
CO-00130
2) Remove the clip which holds the fan motor onto the shroud.
Hood stay holder Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
CO-00133
D: ASSEMBLY
Assemble in the reverse order of disassembly.
CO-02017
CO-00133
CO-00132
CO(H6DO)-20

COOLING
E: INSPECTION
1) Disconnect the connector from radiator fan control unit. NOTE: Do not remove the main fan motor harness connector.
CO-02018
2) Connect the battery to radiator fan control unit as shown in the figure.
CO-02037
3) Check the fan motor for operations. If it does not operate, check the fan motor.
CO(H6DO)-21

COOLING

A: REMOVAL
7) Remove the bolts which hold the sub fan shroud to the radiator.
CO-00129
8) Lift up the vehicle. 9) Remove the under cover. 10) Remove the radiator sub fan shroud through the under side of vehicle.
IN-00203
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Check if the radiator hose and the over flow hose are properly connected. Radiator sub fan shroud assembly Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
CO-02017
CO-00129
Hood stay holder Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
CO-02029
CO-02017
CO(H6DO)-22

COOLING
C: DISASSEMBLY
1) Remove the nut which holds fan to fan motor and shroud assembly.
CO-00136 CO-00136
E: INSPECTION
1) Disconnect the connector from radiator fan control unit. NOTE: Do not remove the main fan motor harness connector.
2) Remove the clip which holds the fan motor onto the shroud.
CO-00133
3) Remove the bolts which hold the radiator fan control unit to the shroud.
D: ASSEMBLY
Assemble in the reverse order of disassembly. Radiator fan control unit bolt tightening torque: 5.4 Nm (0.6 kgf-m, 4.0 ft-lb) Tightening torque: 3.8 Nm (0.4 kgf-m, 2.8 ft-lb)
CO-02018
2) Connect the battery to radiator fan control unit as shown in the figure.
CO-02037
3) Check the fan motor for operations. If it does not operate, check the fan motor.
CO-00133
CO(H6DO)-23
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose. 2) Remove the bolts which hold the reservoir tank to the fan shroud, then remove the reservoir tank.
CO-02241
B: INSTALLATION
C: INSPECTION
CO(H6DO)-24
Radiator Fan Control Unit

COOLING
11.Radiator Fan Control Unit

A: SPECIFICATION
Radiator fan control unit forms a unit with radiator sub fan motor. Refer to Radiator Sub Fan and Fan Motor for removal and installation procedures. <Ref. to CO(H6DO)-22, REMOVAL, Radiator Sub Fan and Fan Motor.> <Ref. to CO(H6DO)-22, INSTALLATION, Radiator Sub Fan and Fan Motor.> <Ref. to CO(H6DO)-23, DISASSEMBLY, Radiator Sub Fan and Fan Motor.> <Ref. to CO(H6DO)-23, ASSEMBLY, Radiator Sub Fan and Fan Motor.>
CO(H6DO)-25

COOLING

A: INSPECTION
Trouble Possible cause a. Insufficient engine coolant b. Defective thermostat c. Malfunction of water pump d. Clogged engine coolant passage e. Improper ignition timing f. Clogged or leaking radiator Overheating g. Improper engine oil in engine coolant h. Air/fuel mixture ratio too lean i. Excessive back pressure in exhaust system j. Insufficient clearance between piston and cylinder k. Dragging brake l. Defective radiator fan Over-cooling a. Ambient temperature extremely low b. Defective thermostat a. Loosened or damaged connecting units on hoses b. Leakage from water pump c. Leakage from water pipe d. Leakage around cylinder head gasket e. Damaged or cracked cylinder head and cylinder block f. Damaged or cracked thermostat cover g. Leakage from radiator a. Defective radiator fan b. Defective water pump bearing c. Mechanical water pump malfunction Corrective action Replenish engine coolant, inspect for leakage, and repair it if necessary. Replace. Replace. Clean. Inspect and repair ignition control system. <Ref. to EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.> Clean, repair or replace. Replace engine coolant. If ineffective, check, repair or replace engine components. Inspect and repair the fuel injection system. <Ref. to EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.> Clean or replace. Adjust or replace. Adjust. Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them. Partly cover radiator front area. Replace. Repair or replace. Replace. Repair or replace. Retighten cylinder head bolts or replace gasket. Repair or replace. Repair or replace. Repair or replace. Replace. Replace water pump. Replace water pump.
Noise
CO(H6DO)-26
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method Pump type Inner rotor Outer rotor Oil pump Outer rotor diameter thickness mm (in) Tip clearance between inner and outer rotors mm (in) Side clearance between inner rotor and pump case mm (in) Case clearance between outer rotor and pump case mm (in) Filter type Filtration area cm2 (sq in) Oil filter By-pass valve opening pressure kPa (kg/cm2, psi) Outer diameter width mm (in) Installation screw specifications Relief valve working pressure kPa (kg/cm2, psi) Number of teeth Oil pressure switch Type Operating voltage power consumption Warning light operating pressure Proof pressure Total capacity (Overhaul) When replacing engine oil and oil filter When replacing engine oil only Forced lubrication Trochoid type 7 8 86 13 (3.39 0.51) 0.04 0.14 (0.0016 0.0055) 0.020 0.046 (0.0008 0.0018) 0.110 0.175 (0.0043 0.0069) Full-flow filter type 1,300 (201.5) 160 (1.63, 23.2) 80 75 (3.15 2.95) M 20 1.5 708 (7.22, 102.7) Immersed contact point type 12 V 3.4 W or less 15 (0.15, 2.2) 980 (10.0, 142) or more 7.0 (7.4, 6.2) 5.7 (6.0, 5.0) 5.5 (5.8, 4.8)
Engine oil
kPa (kg/cm2, psi) kPa (kg/cm2, psi) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt)
Recommended oil: Oil corresponding to either of the following standards. For API standard, oil with SM Energy Conserving logo For ILSAC standard, oil with GF-4 Star burst mark label on the container
SAE (1) ( C) -30 -20 -15 ( F) -22 -4 5
NOTE: The proper viscosity oil helps the engine maintain its ideal temperature, and cranking speed increased by reducing viscosity friction in hot condition. If the vehicle is used in regions of high temperatures or in other severe environments, use oil with the viscosities shown below. API standard: SM or SL SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W50
0 32
15 59
30
40
86 104
10W-30, 10W-40 , 10W-50 5W-30 (2)
LU-02329
(1) SAE viscosity No. and applicable temperature (2) Recommended
CAUTION: It is acceptable to fill an engine with oil of another brand when replacing the oil, but make sure to use an oil with an API standard and SAE viscosity number specified by Subaru.
LU(H6DO)-2
General Description
LUBRICATION
B: COMPONENT
(14) (13) (15) (12) T2 T6 (20) (9) T10 T9 (19) (8) T3 (7) (6) (7)
(5)
T7 (17) (6) (7)
(26) (26)
(16)
(10)
(7)
(11)
(18)
T4 T4
T4 T5 (7) (7)
(21) (25) (24)
(26)
(22) T1
(23) (6) T8
T4
(2)
(1) T1 T8 (3) (4)
T1
LU-02368
LU(H6DO)-3
General Description
LUBRICATION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Oil pan lower Magnet Drain plug Gasket Engine oil cooler water pipe Water hose Clip Gasket Oil cooler Oil cooler connector Oil filter Oil pump cover Inner rotor (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) Outer rotor Crank sprocket Oil pan upper Plug Plug Plug Oil pressure switch Plug Oil strainer Plug Relief valve spring Relief valve O-ring Tightening torque:Nm (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: <Ref. to LU(H6DO)-9, INSTALLATION, Oil Pump.> T3: T4: T5: T6: T7: T8: T9: T10: 16 (1.6, 11.8) 18 (1.8, 13.3) 23 (2.3, 17.0) 25 (2.5, 18.4) 37 (3.8, 27.3) 44 (4.5, 32.5) 54 (5.5, 39.8) 90 (9.2, 66.4)
LU(H6DO)-4
General Description
LUBRICATION
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. Prepare a container and cloth to prevent scattering of oil when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. Follow all government and local regulations concerning disposal of refuse when disposing oil.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 499977100 DESCRIPTION CRANK PULLEY WRENCH REMARKS Used to stop rotation of the crank pulley when loosening or tightening crank pulley bolts.
ST-499977100
498547000
OIL FILTER WRENCH
Used for removing and installing oil filter.
ST-498547000
LU(H6DO)-5
Oil Pressure System

LUBRICATION
2. Oil Pressure System

A: WIRING DIAGRAM
OIL PRESSURE WARNING LIGHT
COMBINATION METER i10
15 i3 17 B38 31 B21 E2
E11
E
OIL PRESSURE SWITCH
B21 B72 1 2 3 4 5 6 i10 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22 B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
LU-02306
LU(H6DO)-6
Oil Pressure System

LUBRICATION
B: INSPECTION
1 Step Check CHECK COMBINATION METER. Does the warning light illumi1) Turn the ignition switch to ON. (engine OFF) nate? 2) Check the warning light of combination meter. Yes Go to step 2. No Repair or replace the combination meter. <Ref. to IDI5, INSPECTION, Combination Meter System.> Go to step 3.
CHECK HARNESS CONNECTOR BETWEEN Is the voltage 10 V or more? COMBINATION METER AND OIL PRESSURE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from oil pressure switch. 3) Turn the ignition switch to ON. 4) Measure the voltage between oil pressure switch connector and engine ground. Connector & terminal (E11) No. 1 (+) Engine ground (): CHECK COMBINATION METER. Is the resistance less than 10 :? 1) Turn the ignition switch to OFF. 2) Remove the combination meter. 3) Measure the resistance of combination meter. Terminals (i10) No. 3 (i10) No. 15:
Replace the oil pressure switch. <Ref. to LU(H6DO)-15, Oil Pressure Switch.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between combination meter and oil pressure switch Poor contact in combination meter connector Poor contact in oil pressure switch connector Poor contact of coupling connector
Repair or replace the combination meter. <Ref. to IDI5, INSPECTION, Combination Meter System.>
LU(H6DO)-7
Engine Oil
LUBRICATION
3. Engine Oil
A: INSPECTION
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe away the oil. 3) Reinsert the oil level gauge all the way. Be sure that the oil level gauge is correctly inserted and properly orientated. 4) Pull out the oil level gauge again, and check the oil level. If the engine oil level is below L line, make sure that there is no oil leakage from the engine, then add oil to rise the level up to the F line. 5) After turning off the engine, wait a few minutes for the oil to return to the oil pan before checking the oil level. NOTE: Just after driving or while the engine is warm, engine oil level may over F line. This is caused by thermal expansion of engine oil. To prevent overfilling of engine oil, do not add oil above F line when the engine is cold.
(B) (A)
F
NOTE: Prepare the container for draining of engine oil.
LU-02011
5) Tighten the engine oil drain plug after draining engine oil. NOTE: Use a new drain plug gasket. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) 6) Lower the vehicle. 7) Using engine oil of proper quality and viscosity, fill engine oil through the oil filler duct to the F line on the level gauge. Make sure that the vehicle is parked on a level surface when checking oil level. Recommended oil: Refer to SPECIFICATION for the recommended oil. <Ref. to LU(H6DO)-2, SPECIFICATION, General Description.> Engine oil capacity: Refer to SPECIFICATION for the engine oil capacity. <Ref. to LU(H6DO)-2, SPECIFICATION, General Description.> 8) Close the engine oil filler cap. 9) Start the engine, and spreads the oil in engine room. 10) After stopping the engine, recheck the oil level. If necessary, add engine oil up to the F line on the level gauge.
(B) (A)
F L
(C) (E)
(D)
LU-02330
(A) (B) (C) (D) (E)
Oil level gauge Engine oil filler cap F line L line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
(C) (E) (D)
B: REPLACEMENT
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Set the vehicle on a lift. 2) Open the engine oil filler cap for quick draining of engine oil. 3) Lift up the vehicle. 4) Drain engine oil by loosening the engine oil drain plug.
LU-02330
(A) (B) (C) (D) (E)
Oil level gauge Engine oil filler cap F line L line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
LU(H6DO)-8
Oil Pump
LUBRICATION
4. Oil Pump
A: REMOVAL
B: INSTALLATION
1) Apply a coat of engine oil to the whole area of inner rotor and outer rotor.
LU-02032
IN-00203
4) Lift up the vehicle. 5) Remove the under cover. 6) Drain engine coolant. <Ref. to CO(H6DO)-10, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 7) Lower the vehicle. 8) Remove the radiator. <Ref. to CO(H6DO)-15, REMOVAL, Radiator.> 9) Remove the V-belts. <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 10) Remove the front chain cover. <Ref. to ME(H6DO)-44, REMOVAL, Front Chain Cover.> 11) Remove the timing chain assembly. <Ref. to ME(H6DO)-46, REMOVAL, Timing Chain Assembly.> 12) Remove the crank sprocket. 13) Remove the oil pump cover.
2) Install the inner rotor to crankshaft and assemble the outer rotor. 3) Install the oil pump cover. 4) Tighten the bolts in the numerical order as shown in the figure. CAUTION: Make sure that the bolt is installed in correct position. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(3) (9) (5) (8) (12) (16) (17) (15) (13) LU-02013 (11) (1) (6) (7) (2) (4) (10) (14)
Bolt installing position (1) and (3) (2) and (4) (5), (6), (7), (8), (9), (10) and (11) (12), (15), (16) and (17) (13) and (14)
LU-02012
Bolt dimension 6 14 14 6 35 18 6 35 15 6 16 16 6 26 15
14) Remove the inner rotor and outer rotor.
5) Install the crank sprocket. 6) Install the timing chain assembly. <Ref. to ME(H6DO)-47, INSTALLATION, Timing Chain Assembly.> 7) Install the front chain cover. <Ref. to ME(H6DO)44, INSTALLATION, Front Chain Cover.> 8) Install the V-belts. <Ref. to ME(H6DO)-42, INSTALLATION, V-belt.> 9) Install the radiator. <Ref. to CO(H6DO)-16, INSTALLATION, Radiator.> 10) Lift up the vehicle. 11) Install the under cover. 12) Lower the vehicle.
LU(H6DO)-9
Oil Pump
LUBRICATION
C: INSPECTION
1. TIP CLEARANCE
Measure the tip clearance of rotors. If the clearance exceeds specification, replace the rotors as a matched set. Tip clearance: Standard 0.04 0.14 mm (0.0016 0.0055 in)
3. SIDE CLEARANCE
Measure the clearance between oil pump inner rotor and rear chain cover. If the clearance exceeds specification, replace the rotors as a matched set. Side clearance: Specification 0.020 0.046 mm (0.0008 0.0018 in)
LU-02016 LU-02014
2. CASE CLEARANCE
Measure the clearance between the outer rotor and rear chain cover rotor housing. If the clearance exceeds the standard value, replace the outer rotor. Case clearance: Standard 0.110 0.175 mm (0.0043 0.0069 in)
Perform the replacement part selection as follows. When replacing all of inner rotor, outer rotor and rear chain cover with new parts, use those with matching identification marks as there are identification marks on those parts in the locations shown on the figure.
LU-02015
ME-02734
LU(H6DO)-10
Oil Pump
LUBRICATION
When replacing any of inner rotor, outer rotor and rear chain cover with a new part, select the suitable size from the following table so that side clearance is within the standard value. Inner rotor
Identification A None C Part No. 15015AA250 15015AA300 15015AA310 Rotor thickness mm (in) 12.993 13.006 (0.51153 0.51205) 12.980 12.993 (0.51102 0.51153) 12.967 12.980 (0.51051 0.51102)
Outer rotor
Identification A None C Part No. 15016AA250 15016AA300 15016AA310 Rotor thickness mm (in) 12.993 13.006 (0.51153 0.51205) 12.980 12.993 (0.51102 0.51153) 12.967 12.980 (0.51051 0.51102)
Rear chain cover

Identification A B C Part No. 13119AA020 13119AA050 13119AA060 Rotor thickness mm (in) 13.026 13.039 (0.51295 0.51335) 13.013 13.026 (0.51232 0.51284) 13.000 13.013 (0.51181 0.51232)
4. OIL PUMP CASE

Check the worn shaft hole, clogged oil passage, crank and other parts for faults.
LU(H6DO)-11
Oil Pump Relief Valve

LUBRICATION
5. Oil Pump Relief Valve

A: REMOVAL
1. REAR CHAIN COVER SIDE
Oil pump relief valve is integrated into oil pump cover as one unit; therefore, refer to Oil Pump for removal procedure. <Ref. to LU(H6DO)-9, REMOVAL, Oil Pump.>
B: INSTALLATION
1. REAR CHAIN COVER SIDE
Oil pump relief valve is integrated into oil pump cover as one unit; therefore, refer to Oil Pump for installation procedure. <Ref. to LU(H6DO)-9, INSTALLATION, Oil Pump.>
2. OIL PAN UPPER SIDE

1) Install the relief valve, relief valve spring and plug. NOTE: Apply engine oil to the relief valve. Tightening torque: T: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
2. OIL PAN UPPER SIDE

1) Remove the oil pan. <Ref. to LU(H6DO)-13, REMOVAL, Oil Pan and Strainer.> 2) Remove the plug, relief valve spring and relief valve.
(1)
(2)
(3) T
LU-02033
(1) Relief valve (2) Relief valve spring (3) Plug
LU-02034
2) Install the oil pan. <Ref. to LU(H6DO)-13, INSTALLATION, Oil Pan and Strainer.>
C: INSPECTION
Check the worn shaft hole of oil pump relief valve case, clogged oil passage, crank and other parts for faults.
LU(H6DO)-12

LUBRICATION
6. Oil Pan and Strainer

A: REMOVAL
NOTE: Before removing the oil pan upper, remove the engine from vehicle. <Ref. to ME(H6DO)-34, REMOVAL, Engine Assembly.> <Ref. to ME(H6DO)64, REMOVAL, Cylinder Block.> 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain the engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> 5) Insert an oil pan cutter blade into the gap between oil pan upper and oil pan lower, and remove the oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter. 6) Remove the oil pan lower.
B: INSTALLATION
NOTE: Before installing the oil pan, wipe and clean the mating surface of oil pan lower and oil pan upper. 1) Install the oil strainer onto oil pan upper. NOTE: Use new O-rings. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
LU-00123
7) Remove the oil strainer.
LU-02108
2) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: Install within 5 minutes after applying liquid gasket. Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Applying liquid gasket diameter: 5.0r1.0 mm (0.197r0.039 in)
LU-00125 LU-02108
LU(H6DO)-13

LUBRICATION
3) Tighten the oil pan lower installing bolts in the numerical order as shown in the figure. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(2) (3) (4) (5) (6) (7) (8) (9) LU-00126 (1) (15) (14) (13) (12) (11) (10)
4) Install the under cover. 5) Lower the vehicle. 6) Refill the engine oil. <Ref. to LU(H6DO)-8, INSPECTION, Engine Oil.>
C: INSPECTION
Visually check that the oil pan, oil strainer and oil strainer stay are not damaged.
LU(H6DO)-14
Oil Pressure Switch

LUBRICATION
7. Oil Pressure Switch

A: REMOVAL
B: INSTALLATION
1) Apply liquid gasket to the oil pressure switch threads. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent
IN-00203
3) Lift up the vehicle. 4) Remove the under cover. 5) Disconnect the terminal from oil pressure switch.
LU-00129
2) Install the oil pressure switch. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
LU-02126
6) Remove the oil pressure switch.

LU-02127
3) Connect the terminal of the oil pressure switch.
LU-02127 LU-02126
C: INSPECTION
Make sure oil does not leak or seep from where the oil pressure switch is installed.
LU(H6DO)-15
Engine Oil Filter

LUBRICATION

A: REMOVAL
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain the engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> 5) Remove the oil filter using ST. ST 4985447000 OIL FILTER WRENCH
LU-02035
B: INSTALLATION
CAUTION: Do not tighten excessively, or oil may leak. 1) Clean the oil filter installation surface of the oil cooler. 2) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install the oil filter turning it by hand, being careful not to damage the seal rubber. 4) Tighten more (approx. 3/4 turn) after the seal rubber contacts the oil cooler. When using a torque wrench, tighten to 14 Nm (1.4 kgf-m, 10.3 ft-lb). 5) Install the under cover. 6) Lower the vehicle. 7) Refill the engine oil. <Ref. to LU(H6DO)-8, INSPECTION, Engine Oil.>
C: INSPECTION
1) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 2) Check the engine oil level. <Ref. to LU(H6DO)8, INSPECTION, Engine Oil.>
LU(H6DO)-16
Oil Cooler
LUBRICATION
9. Oil Cooler
A: REMOVAL
CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Set the vehicle on a lift. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine coolant. <Ref. to CO(H6DO)-10, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 5) Drain the engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> 6) Remove the bolts which hold the engine oil cooler water pipe to engine.
9) Remove the oil cooler connector and remove the oil cooler.
(A) (B) (C) LU-02130
(A) Oil cooler connector (B) Oil cooler (C) Gasket
LU-02128
7) Disconnect the water hose from oil cooler.
LU-02129
8) Remove the oil filter using the ST. <Ref. to LU(H6DO)-16, REMOVAL, Engine Oil Filter.>
LU(H6DO)-17
Oil Cooler
LUBRICATION
B: INSTALLATION
1) Install the oil cooler to oil pan upper with oil cooler connector. NOTE: Use a new gasket. Tightening torque: T: 54 Nm (5.5 kgf-m, 39.8 ft-lb)
(A)
7) Fill engine coolant. <Ref. to CO(H6DO)-10, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 8) Check the engine oil level. <Ref. to LU(H6DO)8, INSPECTION, Engine Oil.>
C: INSPECTION
1) Check that coolant passages are not clogged using an compressed air. 2) Check that the oil pan upper and O-ring installing surface of oil filter are not damaged.
T (B) (C) LU-02131
(A) Oil cooler connector (B) Oil cooler (C) Gasket
2) Install the oil filter. <Ref. to LU(H6DO)-16, INSTALLATION, Engine Oil Filter.> 3) Connect the water hose.
LU-02129
4) Install the engine oil cooler water pipe onto engine. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
LU-02128
5) Lower the vehicle. 6) Refill the engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.>
LU(H6DO)-18

LUBRICATION
10.Engine Lubrication System Trouble in General

A: INSPECTION
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Symptom Possible cause Cracked diaphragm or oil leakage within switch Broken spring or seized contacts Clogging of oil filter Malfunction of oil by-pass valve in oil filter Malfunction of oil relief valve in oil pump 2) Low oil pressure Clogged oil passage Excessive tip clearance and side clearance of oil pump rotor and gear Clogged oil strainer or broken pipe Insufficient engine oil (including deterioration) 3) No oil pressure Broken pipe of oil strainer Stuck oil pump rotor 1) Malfunction of combination meter 2) Poor contact of switch contact points 3) Disconnection of wiring 1) Poor contact of terminals 2) Defective wiring harness 1) Oil pressure switch failure 3) Low oil pressure Corrective action Replace. Replace. Replace. Clean or replace. Clean or replace. Clean. Replace. Clean or replace. Replace. Replace. Replace. Replace. Replace. Repair. Repair. Repair. Check for the same possible causes as listed 1. 2).
1. Warning light remains on.
2. Warning light does not turn on.
3. Warning light flickers momentarily.
LU(H6DO)-19

LUBRICATION
LU(H6DO)-20
General Description
A: SPECIFICATION
Specifications for the 3.0 L DOHC non-turbo model are the same as the 2.0 L SOHC non-turbo model. <Ref. to SP(H4SO)-2, General Description.>
SP(H6DO)-2
General Description
IGNITION
A: SPECIFICATION
Item Ignition coil Type Ignition system Manufacturer Manufacturer and type Thread size (diameter, pitch, length) Spark plug gap Electrode Specification FK0333 Independent ignition coil Diamond Electric NGK: ILFR6B 14, 1.25, 26.5 0.7 0.8 (0.028 0.031) Iridium
Spark plug
mm mm (in)
B: COMPONENT
T1
(1) (2)
T2
(1) (2) T2
T1
IG-00052
(1)
Spark plug
(2)
Ignition coil
IG(H6DO)-2
General Description
IGNITION
C: CAUTION
IG(H6DO)-3
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
Spark plug: Refer to SPECIFICATION for the spark plug. <Ref. to IG(H6DO)-2, SPECIFICATION, General Description.>
1. RH SIDE
IG-02005
(B)
(B)
(C)
(D)
(A) IN-00203
IG-02011
3) Remove the air cleaner case. <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.> 4) Remove the bracket (A). 5) Disconnect the connector (B) from ignition coil.
(A) (B) (C) (D)
(A)
2. LH SIDE
1) Remove the collector cover. 2) Remove the battery and battery carrier. <Ref. to SC(H4SO)-20, REMOVAL, Battery.> 3) Remove the bracket (A). 4) Disconnect the connector (B) from ignition coil.
(B)
IG-02004
(A)
(B)
IG-02006
IG(H6DO)-4
Spark Plug
IGNITION
C: INSPECTION
(A) (B)
(C)
IG-02007 (D) (E) IG-00010
(B)
(B)
(C)
(D)
(A)
(A) (B) (C) (D) (E)
Spark plug gap Carbon accumulation or wear Crack Damage Damaged gasket
IG-02011
(A) (B) (C) (D)
B: INSTALLATION
1. RH SIDE
IG-00011
2. LH SIDE
IG-00012
IG(H6DO)-5
Spark Plug
IGNITION
3) Oil fouled: Wet black deposits show oil entrance into the combustion chamber through worn rings and excessive clearance between valve guides and stems.
IG-00013
IG-00014
D: ADJUSTMENT
Clean spark plugs with a nylon brush, etc. Clean and remove the carbon or oxide deposits. If deposits are too stubborn, replace the spark plugs. After cleaning the spark plugs, measure the spark plug gap using a gap gauge. NOTE: Never use a plug cleaner. Never use a metal brush because it makes insulator worn. Spark plug gap L: 0.7 0.8 mm (0.028 0.031 in)
IG-02035
IG(H6DO)-6
Ignition Coil
IGNITION
3. Ignition Coil
A: REMOVAL
Direct ignition type has been adopted. Refer to Spark Plug for removal procedure. <Ref. to IG(H6DO)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
C: INSPECTION
For inspection procedure, refer to Diagnostics for Engine Starting Failure. <Ref. to EN(H6DO)(diag)73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
IG(H6DO)-7
Ignition Coil
IGNITION
IG(H6DO)-8
General Description
A: SPECIFICATION
Specifications for the 3.0 L DOHC non-turbo model are included in the SC (H4SO) section. <Ref. to SC(H4SO)-2, General Description.>
SC(H6DO)-2


A: PROCEDURE
1. ENGINE
1 Step Check CHECK ENGINE START FAILURE. Does the engine start? 1) Ask the customer when and how the trouble occurred using the interview checklist. <Ref. to EN(H6DO)(diag)-3, CHECK, Check List for Interview.> 2) Start the engine. Yes Go to step 2. No Inspection using Diagnostics for Engine Start Failure. <Ref. to EN(H6DO)(diag)66, Diagnostics for Engine Starting Failure.> Inspection using General Diagnostic Table <Ref. to EN(H6DO)(diag)353, INSPECTION, General Diagnostic Table.> Inspection using Diagnostics Procedure for Subaru Select Monitor Communication. <Ref. to EN(H6DO)(diag)79, Diagnostic Procedure for Subaru Select Monitor Communication.>
CHECK THE COMMUNICATION STATUS. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor or general scan tool to the data link connector. 3) Turn the ignition switch to ON, and run the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed procedures, refer to Subaru Select Monitor. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK DTC. Read DTC using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR Refer to Read Diagnostic Trouble Code for detailed operation procedure. <Ref. to EN(H6DO)(diag)-43, Read Diagnostic Trouble Code (DTC).> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual.
PERFORM DIAGNOSIS. 1) Perform the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> 2) Perform the Inspection Mode. <Ref. to EN(H6DO)(diag)-44, Inspection Mode.>
Repair the related parts. NOTE: If DTC is not shown on display although the malfunction indicator light illuminates, perform the diagnosis of malfunction indicator light circuit or combination meter. <Ref. to EN(H6DO) (diag)-57, Malfunction Indicator Light.> Finish the diagnoIs DTC displayed on the Subaru Inspect using Select Monitor or general scan Diagnostic Proce- sis. tool? dure with Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)89, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Is DTC displayed on the Subaru Record the DTC. Select Monitor or general scan Repair the trouble cause. <Ref. to tool? EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Go to step 5.
EN(H6DO)(diag)-2


A: CHECK
1. CHECK LIST NO. 1
Place
Engine temperature
ON/ ON/ ON/ ON/ ON/
OFF OFF OFF OFF OFF
EN(H6DO)(diag)-3

2. CHECK LIST NO. 2

Yes /
No
Yes /
No
EN(H6DO)(diag)-4
General Description
A: CAUTION
1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay. CAUTION: Do not use the electrical test equipment on airbag system circuits. Be careful not to damage the airbag system wiring harness when servicing the ECM, TCM, main relay and fuel pump relay. 2) Never connect the battery in reverse polarity. Failure to do so will damage the ECM instantly, and other parts will also be damaged. 3) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as ECM etc. 4) Before disconnecting the connectors of each sensor and ECM, be sure to turn the ignition switch to OFF. Perform the Clear Memory Mode after connecting the connectors. <Ref. to EN(H6DO)(diag)52, Clear Memory Mode.> 5) When measuring the voltage or resistance of individual sensor or all electrical control modules, use a tapered pin with a diameter of less than 0.6 mm (0.024 in). Do not insert the pin 4 mm (0.16 in) or more into the part. CAUTION: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system. NOTE: When replacing the ECM of the models with Immobilizer, immobilizer system must be registered. To do so, all ignition keys and ID cards need to be prepared. For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. 6) Take care not to allow water to get into the connector when servicing the vehicle in rainy weather or when washing the vehicle. Avoid exposure to water even if the connectors are waterproof.
(A)
EN-00001
(A) Stud bolt
EN-02473
9) Every engine control system-related part is a precision part. Do not drop them. 10) Observe the following cautions when installing a radio in vehicle. CAUTION: The antenna must be kept as far apart as possible from control module. (The ECM is located under the passengers seat floor mat.) The antenna feeder must be placed as far apart as possible from the ECM and engine control system harness. Carefully adjust the antenna for correct matching. When mounting a large power type radio, pay special attention to the three items mentioned above. Incorrect installation of the radio may affect the operation of ECM. 11) When disconnecting the fuel hose, release the fuel pressure. <Ref. to FU(H6DO)-43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
EN(H6DO)(diag)-5
General Description
C: NOTE
B: INSPECTION
1. BATTERY
2. ENGINE GROUND
EN-02473
EN(H6DO)(diag)-6
General Description
D: PREPARATION TOOL
ST1B022XU0
18252AA000
CRANKSHAFT SOCKET
ST18252AA000
EN(H6DO)(diag)-7


A: LOCATION
1. CONTROL MODULE
(3) (1)
(2)
(4) EN-05722
(1) (2)
(3)
(4)
Data link connector
(1)
CHECK ENGINE
EN-01147
(2)
EN-03104
(4) (3)
EN-02975
AT-01877
EN(H6DO)(diag)-8

2. SENSOR
(6)
(5)
(4)
(7)
(5)
(6) (8)
(1)
(2)
(3)
EN-02478
(1) (2)
Mass air flow and intake air temperature sensor Manifold absolute pressure sensor
(3) (4) (5)
Engine coolant temperature sensor Electronic throttle control Knock sensor
(6) (7) (8)
Camshaft position sensor Crankshaft position sensor Oil temperature sensor
EN(H6DO)(diag)-9

(1)
(2) EN-02479 (4) (3) EN-02535
EN-00895
EN-02536
(5)
(6)
(5) EN-00897 EN-02537
(7)
(8) EN-00899 EN-02538
EN(H6DO)(diag)-10

(7)
(2)
(4)
(6)
(1)
(3)
(5)
EN-02480
(1) (2) (3)
Front oxygen (A/F) sensor LH Front oxygen (A/F) sensor RH Rear oxygen sensor LH
(4) (5)
Rear oxygen sensor RH Front catalytic converter LH
(6) (7)
Front catalytic converter RH Rear catalytic converter
(2) (5) (1) (6)
EN-02539
EN-02540
(4) (3)
EN-02541
EN-02542
(7) EN-02543
EN(H6DO)(diag)-11

(1) (2) (3)
(4) EN-05723
(1) (2)
(3)
(4)
(3)
(1)
(2) EN-05725 EN-03003
(4)
EN-03132
EN(H6DO)(diag)-12

(2)
(5)
(4)
(1)
(6)
(4)
(5)
(2)
(3)
(3)
EN-05643
(1) (2) (3)
Purge control solenoid valve Ignition coil Oil flow control solenoid valve
(4) (5)
Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch
(6)
EGR valve
EN(H6DO)(diag)-13

(1) EN-02482 (4) (3)
(2) EN-02960
(5)
EN-02961
EN-02962
(6) EN-05006
EN(H6DO)(diag)-14

(1)
(4)
(2)
(3)
EN-05724
(1) (2)
(3)
Drain valve
(4)
Drain filter
(4) (3)
(2) (1) EN-02980 EN-02981
EN(H6DO)(diag)-15

(3) (4) (5) (2)
(1)
(6) EN-05719
(1) (2)
Starter Fuel pump
(3) (4)
Main relay Fuel pump relay
(5) (6)
Electronic throttle control relay Radiator fan relay
(2) (1)
EN-05614
EN-05726
(5)
(4)
(3)
(6) EN-02544 EN-07026
EN(H6DO)(diag)-16


TO A:
B134 2 1 10 9 8 20 19 18 30 29 28
TO B:
B135
TO C:
B136
TO D:
B137
7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31
7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28
6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 17 30 29 28 35 34 33 32 31
7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26
EN-05288
Description Signal (+) Signal () Shield Signal Ground Signal Ground Main Electronic throttle control Sub Electronic throttle control motor (+) Electronic throttle control motor () Electronic throttle control motor power supply Electronic throttle control motor relay Signal A+ Signal A EGR valve Signal B+ Signal B
Connector No. B134 B134 B134 B134 B134 B134 B134 B134
Terminal No. 13 14 24 21 22 11 22 18
Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 0 0 0.275 0 0.275 0 0.64 0.94 Fully opened: 4.01 1.51 1.76 Fully opened: 4.23 Duty waveform Duty waveform 10 13 ON: 0 OFF: 10 13 10 13 10 13 10 13 10 13 7 +7 0 0 0 or 5 0 0 or 5 0 0.64 0.72 (After engine is warmed up.) 1.51 1.58 (After engine is warmed up.) Duty waveform Duty waveform 12 14 ON: 0 OFF: 12 14 12 14 12 14 12 14 12 14
Reference Waveform Waveform Waveform Fully closed: 0.6 Fully opened: 4.01 Fully closed: 1.48 Fully opened: 4.23 Drive frequency: 500 Hz Drive frequency: 500 Hz When ignition switch is turned to ON: ON
Crankshaft position sensor Camshaft position sensor (LH) Camshaft position sensor (RH)
B134 B137 B137 B136 B136 B134 B134 B134 B134
28 5 4 1 21 8 9 10 20
EN(H6DO)(diag)-17

Connector No. B135 B135 B135 B135 B135 B135 B134 B136 B136 B136 B135 B136 B135 B136 B135 B134 B134 B134 B134 B135 B135 B134 B134 B137 B137 B137 B137 B137 B137 B137 B137 B137 B137 B137 B137 B136 Terminal No. 23 21 29 31 22 30 34 32 20 24 14 33 19 31 27 15 25 16 25 5 2 7 19 18 19 20 21 22 23 8 9 10 11 12 13 9 12 14 2.4 0 2.4 0 10 13 10 13 10 13 5 0 0 0 0 0 0 10 13 10 13 10 13 10 13 10 13 10 13 ON: 0.5 or less OFF: 10 13 Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) Fully closed: 1 Fully opened: 3.6 5 0 Fully closed: 1 Fully opened: 3.7 5 0 1.0 1.4 0 ON: 0 OFF: 10 13 ON: 10 13 OFF: 0 Duty waveform ON: 0 OFF: 10 13 10 13 Fully closed: 1 Fully opened: 3.3 5 0 Fully closed: 1 Fully opened: 3.3 5 0 1.0 1.4 0 ON: 0 OFF: 12 14 ON: 12 14 OFF: 0 Duty waveform ON: 0 OFF: 12 14 12 14
Description Main sensor signal Main power supply Ground Accelerator pedal (main sensor) position sensor Sub sensor signal Sub power supply Ground (sub sensor) Engine coolant temperature sensor Starter switch Starter relay A/C switch A/C lock sensor A/C middle pressure switch Ignition switch Neutral position switch Delivery (test) mode connector Signal Knock sensor 1 Shield Signal Knock sensor 2 Shield Back-up power supply Control module power supply Sensor power supply #1 #2 #3 Ignition control #4 #5 #6 #1 #2 #3 Fuel injector #4 #5 #6 A/C relay control
Reference
After engine is warmed up. Cranking: 8 14 Auto A/C model Switch is ON when select lever is shifted into P range or N range. When connected: 0 Ignition switch OFF: 10 13 Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform
ON: 0 OFF: 12r0.5 12 14 2.4 0 2.4 0 12 14 12 14 12 14 5 0 14 0 14 0 14 0 14 0 14 0 14 1 14 1 14 1 14 1 14 1 14 1 14 ON: 0.5 or less OFF: 12 14
EN(H6DO)(diag)-18

Connector No. B135 B136 B136 B136 B136 B136 B137 B134 B134 B135 B135 B135 B135 B135 B135 B135 B136 B136 B135 B135 B135 B135 B135 B135 B135 B136 B135 B135 B136 B136 B136 B135 B136 B135 Terminal No. 16 18 29 23 11 22 29 33 6 26 35 34 18 9 8 1 3 2 11 10 1 7 6 4 1 4 15 1 5 26 34 33 12 20 Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) ON: 0 ON: 0 OFF: 10 13 OFF: 12 14 ON: 0.5 or less ON: 0.5 or less OFF: 10 13 OFF: 12 14 ON: 0.5 or less ON: 0.5 or less OFF: 10 13 OFF: 12 14 0 0 ON: 1 or less OFF: 10 13 ON: 1 or less OFF: 10 13 3.5 4.8 0.74 0 0 3.15 3.33 2.8 3.2 2.4 2.7 0 12 14 12 14 2.8 3.2 2.4 2.7 0 12 14 12 14 0 0 12 14 0 0 12 14 10 10 0 0 When brake pedal is depressed: 0 When brake pedal is released: 10 13 When brake pedal is depressed: 10 13 When brake pedal is released: 0 0 13 or more ON: 1 or less OFF: 12 14 ON: 1 or less OFF: 12 14 1.1 1.9 0.3 4.5 0 0 3.15 3.33 2.8 3.2 2.4 2.7 0 2.8 3.2 2.4 2.7 0 0 0.9 0 0 0.9 0 10 10 12 14 0 or 5 When brake pedal is depressed: 0 When brake pedal is released: 12 14 When brake pedal is depressed: 12 14 When brake pedal is released: 0
Description
Reference
Blower fan switch Radiator fan control Radiator fan control power supply Self-shutoff control Malfunction indicator light Engine speed output Purge control solenoid valve Power steering switch Manifold absolute pressure sensor Signal Air flow sensor Shield Ground Intake air temperature sensor Front oxygen (A/F) sensor RH Front oxygen (A/F) sensor heater RH Front oxygen (A/F) sensor LH Front oxygen (A/F) sensor heater LH Signal (+) Signal () Shield Signal 1 Signal 2 Signal (+) Signal () Shield
Manual A/C model Light ON: 1 or less Light OFF: 10 14 Waveform Intake air temperature: 25C (77F) Waveform Waveform Waveform Waveform Waveform Waveform
Signal 1 Signal 2 Signal Rear oxygen sensor RH Shield Rear oxygen sensor heater RH signal Signal Rear oxygen sensor LH Shield Rear oxygen sensor heater LH signal Immobilizer communication 1 Immobilizer communication 2 Signal 1 Fuel pump control unit Signal 2 Brake switch 1
Brake switch 2
B135
28
EN(H6DO)(diag)-19

Connector No. Terminal No. Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) When not operating: When not operating: 3.5 4.5 3.5 4.5 When operating When operating RES/ACC: 2.5 3.5 RES/ACC: 2.5 3.5 When operating SET/ When operating SET/ COAST: 0.5 1.5 COAST: 0.5 1.5 When operating When operating CANCEL: 0 0.5 CANCEL: 0 0.5 ON: 0 OFF: 5 0 0 0 0 0 0 0 0 1.0 1.4 0 0 0 6.5 1 or less mo 4 or more 10 13 0 0 0 0 0 0 0 0 0 0 0 2.3 ON: 1 or less OFF: 10 13 ON: 1 or less OFF: 10 13 2.5 3.8 2.0 4.5 0.5 3.0 ON: 0 OFF: 5 0.6 0 0.6 0 1.9 0 1.9 0 1.0 1.4 0 0 0 6.5 1 or less mo 4 or more 12 14 0 0 0 0 0 0 0 0 0 0 0 2.7 ON: 1 or less OFF: 12 14 ON: 1 or less OFF: 12 14 2.5 3.8 2.0 4.5 0.5 3.0
Description
Reference
B135
24
Cruise control main switch Signal (+) Oil flow control solenoid valve RH Signal () Signal (+) Oil flow control solenoid valve LH Signal () Signal (+) Oil switching solenoid valve RH Signal () Signal (+) Oil switching solenoid valve LH Signal () Oil temperature sensor signal Variable valve lift diagnosis oil pressure switch RH Variable valve lift diagnosis oil pressure switch LH Generator control SSM communication line Clutch switch GND (sensor) (Ignition 1) (Ignition 2) Engine 1 Engine 2 Engine 3 Ground Engine 4 Engine 5 Engine 6 Body Sensor GND (engine side) Fuel tank pressure sensor Ground (ignition system) Pressure control solenoid valve Drain valve Fuel temperature sensor CAN communication (+) CAN communication ()
B135 B137 B137 B137 B137 B137 B137 B137 B137 B134 B134 B134 B136 B136 B136 B135 B137 B137 B134 B137 B137 B137 B137 B134 B136 B134 B135 B136 B136 B135 B136 B136
12 17 16 15 14 25 24 31 30 23 31 32 10 16 25 30 26 6 5 7 2 1 3 3 6 29 32 28 17 17 27 35
After engine is warmed up. Ambient temperature: 25C (77F) Waveform Waveform
EN(H6DO)(diag)-20

Input/output name 1. Crankshaft position sensor Measuring condition At idling Waveform
10ms 5V
ONE CRANK ROTATION
EN-05357
At idling
RH 0
ONE CAM ROTATION

LH 0
ONE CAM ROTATION
5V 40ms
EN-05358
EN(H6DO)(diag)-21

F/B FUSE No. 4 DATA LINK CONNECTOR
M/B FUSE No. 13 GENERATOR STARTER MOTOR
B5 C10
C25
IGNITION SWITCH C16 F/B FUSE No. 21 STARTER RELAY C20
INHIBITOR RELAY
C32
B27
DELIVERY (TEST) MODE CONNECTOR
C6 C31 B19 B23
JOINT CONNECTOR
TCM F/B FUSE No. 12 FUEL PUMP RELAY
B21 C12 FUEL PUMP CONTROL UNIT B31 B33
M/B FUSE No. 11
B29 FUEL PUMP ASSY FUEL TEMPERATURE SENSOR POWER STEERING OIL PRESSURE SWITCH A33 B17 B22
1
JOINT CONNECTOR B30
2 3 4
EN-06849
EN(H6DO)(diag)-22

SBF No. 5 SBF No. 7
MAIN RELAY
MAIN RELAY 2
RELAY BLOCK D18 IGNITION COIL No. 1
ELECTRONIC THROTTLE CONTROL RELAY C1
D19 IGNITION COIL No. 2 D20 C21 IGNITION COIL No. 3 D21 IGNITION COIL No. 4 C23 D22 IGNITION COIL No. 5 D23 D26 A7 B2 D6 F/B FUSE No. 7 IGNITION COIL No. 6
PURGE CONTROL SOLENOID VALVE
D29 F/B FUSE No. 5 COMBINATION METER MALFUNCTION INDICATOR LIGHT
C11 A21
CAMSHAFT POSITION SENSOR LH
I/F MICRO COMPUTER

CAMSHAFT POSITION SENSOR RH
A11 A22
C22
I/F CAN TRANSCEIVER & RECEIVER
DRAIN VALVE
C17
BODY INTEGRATED UNIT (CAN COMMUNICATION)
TACHOMETER
C28
9
EN-06850
EN(H6DO)(diag)-23

FUEL INJECTOR No. 1
D8
FUEL INJECTOR No. 2
D9
A18
FUEL INJECTOR No. 3
D10 A28
FUEL INJECTOR No. 4
D11
D4
D5 FUEL INJECTOR No. 5 D12 A19
FUEL INJECTOR No. 6
D13
11
A20 A6 A29 MANIFOLD ABSOLUTE PRESSURE SENSOR
A10
EGR VALVE
A34
A9
A8 A23
10
EN-06851
EN(H6DO)(diag)-24

2
B32
B18 B34 B26
A32
VVL DIAGNOSIS OIL PRESSURE SWITCH LH
A31 B35 B7
8
B6 FRONT OXYGEN (A/F) SENSOR LH B11 B10
D15 D14
D17 D16
D31 B9 FRONT OXYGEN (A/F) SENSOR RH B8 C2 C3 D30 OIL SWITCHING SOLENOID VALVE LH
D25 D24 OIL SWITCHING SOLENOID VALVE RH
4
B1 C5
A13 A14 A24 CRANKSHAFT POSITION SENSOR
B15
10
A15 KNOCK SENSOR No. 1
5
B4 REAR OXYGEN SENSOR RH
C4
A16
KNOCK SENSOR No. 2
A25
12
EN-06852
EN(H6DO)(diag)-25

C24 STOP LIGHT SWITCH B28
AUTO A/C CONTROL MODULE
BRAKE SWITCH
B20 C33
A/C PRESSURE SWITCH
C9
A/C RELAY
B12
B14
A/C LOCK SENSOR
AUTO A/C MODEL
C26 BODY INTEGRATED UNIT (IMMOBILIZER) B16 C34 BLOWER FAN RELAY MANUAL A/C MODEL
C27 BODY INTEGRATED UNIT (CAN COMMUNICATION) C35 D7 A5 D3 A3 RADIATOR FAN CONTROL UNIT C18 D2 D1
11
12
MAIN FAN RELAY
C29
ENGINE GROUND
EN-06853
EN(H6DO)(diag)-26


Contents Engine Load Specification 17.9 38.8(%): Idling 16.6 33.7(%): 2,500 rpm racing
Measuring condition: After engine is warmed up. Select lever: P range or N range Turn the A/C off. Turn all the accessory switches to OFF.
EN(H6DO)(diag)-27
Data Link Connector


A: NOTE
9 10 11 12 13 14 15 16
EN-04893
Terminal No. 1 2 3 4 5 6 7 8
Contents Blank Blank Blank Ground Ground CAN communication (+) Subaru Select Monitor signal Blank
Terminal No. 9 10 11 12 13 14 15 16
Contents Blank Blank Blank Blank Blank CAN communication () Blank Power supply
EN(H6DO)(diag)-28
General Scan Tool


A: OPERATION
EN-02533
3) Using the general scan tool, call up DTC and freeze frame data. General scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain DTC (4) MODE $04: Clear/Reset emission-related diagnostic information (5) MODE $06: Request on-board monitoring test results for intermittently monitored systems (6) MODE $07: Request on-board monitoring test results for continuously monitored systems (7) MODE $09: Request vehicle information Read out the data according to repair procedures. (For detailed operation procedure, refer to the general scan tool operation manual.) NOTE: For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)-81, List of Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-29
General Scan Tool

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

PID $01 $03 $04 $05 $06 $07 $08 $09 $0B $0C $0D $0E $0F $10 $11 $13 $15 $15 $19 $19 $1C $1F $21 $24 $28 $2C $2D $2E $2F $30 $31 $32 $33 $34 $34 $38 $38 $3C $3D $41 $42 $43 $44 $45 $46 $47 $49 $4A Data Number of emission-related powertrain DTC and malfunction indicator light status Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim (Bank 1) Long term fuel trim (Bank 1) Short term fuel trim (Bank 2) Long term fuel trim (Bank 2) Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Air flow rate of manifold absolute pressure sensor Throttle valve absolute opening angle Check whether oxygen sensor is installed. Oxygen sensor output voltage (Bank 1 Sensor 2) Oxygen sensor compensation (Bank 1 Sensor 2) Oxygen sensor output voltage (Bank 2 Sensor 2) Oxygen sensor compensation (Bank 2 Sensor 2) On-board diagnostic system Elapsed time after starting the engine Travel distance after the malfunction indicator light illuminates Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank 1) Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank 2) Target EGR EGR deviation Evaporative purge Fuel level Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure Atmospheric pressure A/F sensor lambda value (Bank 1 Sensor 1) A/F sensor current value (Bank 1 Sensor 1) A/F sensor lambda value (Bank 2 Sensor 1) A/F sensor current value (Bank 2 Sensor 1) Catalyst temperature #1 Catalyst temperature #2 Diagnosis monitoring per drive cycle ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Unit of measure % C % % % % kPa rpm MPH C g/s % V % V % sec miles and V and V % % % % miles Pa kPa mA mA C C V % % C % % %
EN(H6DO)(diag)-30
General Scan Tool

PID $4C $4D $4E $51 $5A Data Target throttle opening angle Engine operating time while malfunction indicator light Elapsed time after DTC clear Fuel used Relative acceleration opening angle Unit of measure % min min %

PID $02 $03 $04 $05 $06 $07 $08 $09 $0B $0C $0D $0E $0F $10 $11 $13 $15 $15 $19 $19 $1C $1F $2C $2D $2E $2F $32 $33 $42 $43 $44 $45 $46 $47 $49 $4A $4C Data DTC that caused the freeze frame data storage required by CARB Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim (Bank 1) Long term fuel trim (Bank 1) Short term fuel trim (Bank 2) Long term fuel trim (Bank 2) Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Air flow rate of manifold absolute pressure sensor Throttle valve opening angle Air fuel ratio sensor Oxygen sensor output voltage (Bank 1 Sensor 2) Oxygen sensor compensation (Bank 1 Sensor 2) Oxygen sensor output voltage (Bank 2 Sensor 2) Oxygen sensor compensation (Bank 2 Sensor 2) On-board diagnostic system Elapsed time after starting the engine Target EGR EGR deviation Evaporative purge Fuel level Fuel tank pressure Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Unit of measure % C % % % % kPa rpm MPH C g/s % V % V % sec % % % % Pa kPa V % % C % % % %
NOTE: Refer to general scan tool manufacturers operation manual to access freeze frame data (MODE $02).
EN(H6DO)(diag)-31
General Scan Tool


Refer to List of Diagnostic Trouble Code (DTC) for information about data denoting emission-related powertrain DTC. <Ref. to EN(H6DO)(diag)-81, List of Diagnostic Trouble Code (DTC).>

6. MODE $06
OBDMID TID $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $89 $8A $93 $94 $95 $96 $97 $98 $99 $9A $9B SID $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $20 $FD $FE $FE $FE $FE $FE $FE $24 $24 $14 Diagnostic item A/F sensor conduction abnormal (Bank 1 Sensor 1)
$01
$02
Oxygen sensor response abnormal (Bank 1 Sensor 2)
A/F sensor conduction abnormal (Bank 2 Sensor 1)
$05
$06
Oxygen sensor response abnormal (Bank 2 Sensor 2) Catalyst degradation diagnosis (Bank 1) EGR system diagnosis Evaporative emission control system (Cap off) Evaporative emission control system (0.04 inch leak) Evaporative emission control system (0.02 inch leak) Evaporative emission control system (Purge flow) A/F sensor heater abnormal (Bank 1 Sensor 1) A/F sensor heater characteristic abnormal (Bank 1 Sensor 1)
$21 $31 $39 $3B $3C $3D $41
EN(H6DO)(diag)-32
General Scan Tool

OBDMID $42 TID $9C $9D $99 $9A $9B $9C $9D $0B $0C $0B $0C $0B $0C $0B $0C $0B $0C $1B $1C $1B $1C SID $24 $24 $24 $24 $14 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 Diagnostic item Oxygen sensor heater abnormal (Bank 1 Sensor 2) A/F sensor heater abnormal (Bank 2 Sensor 1) A/F sensor heater characteristic abnormal (Bank 2 Sensor 1) Oxygen sensor heater abnormal (Bank 2 Sensor 2) Misfire monitoring (All cylinders) Misfire monitoring (#1 cylinder) Misfire monitoring (#2 cylinder) Misfire monitoring (#3 cylinder) Misfire monitoring (#4 cylinder) Misfire monitoring (#5 cylinder) Misfire monitoring (#6 cylinder)
$45
$46 $A1 $A2 $A3 $A4 $A5 $A6 $A7
7. MODE $07
8. MODE $09
Refer to the data of vehicle specification (V.I.N., calibration ID, diagnosis frequency, etc.).
EN(H6DO)(diag)-33


A: OPERATION
1) Prepare the Subaru Select Monitor kit. <Ref. to EN(H6DO)(diag)-7, PREPARATION TOOL, General Description.>
EN-05692
EN-02533
EN(H6DO)(diag)-34


Contents Engine Load Engine coolant temperature signal A/F correction 1 A/F learning 1 A/F correction 2 A/F learning 2 Intake manifold absolute pressure Engine speed signal Meter vehicle speed signal Ignition timing signal Intake air temperature signal Intake air amount Throttle opening angle signal Front oxygen sensor voltage value 1 Front oxygen sensor voltage value 2 Battery voltage Mass air flow voltage Injection 1 pulse width Injection 2 pulse width Atmospheric pressure signal Intake manifold relative pressure Fuel tank pressure signal Ignition timing learning value Acceleration opening angle signal Fuel temperature signal Radiator fan output Purge control solenoid valve duty ratio Number of EGR steps Fuel pump duty Variable valve timing advance angle amount R Variable valve timing advance angle amount L Oil flow control solenoid valve duty R Oil flow control solenoid valve duty L Display Engine Load Coolant Temp. A/F Correction #1 A/F Learning #1 A/F Correction #2 A/F Learning #2 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition Timing Intake Air Temp. Mass Air Flow Throttle Opening Angle Front O2 Sensor #1 Front O2 Sensor #2 Battery Voltage Air Flow Sensor Voltage Fuel Injection #1 Pulse Fuel Injection #2 Pulse Atmosphere Pressure Mani. Relative Pressure Fuel Tank Pressure Learned Ignition Timing Accel. Opening Angle Fuel Temp. Radiator Fan Control CPC Valve Duty Ratio No. of EGR steps Fuel Pump Duty VVT Adv. Ang. Amount R VVT Adv. Ang. Amount L OCV Duty R OCV Duty L Unit of measure % C or F % % % % mmHg, kPa, inHg or psig rpm km/h or MPH deg C or F g/s or lb/m % V V V V ms ms mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig deg % C or F % % STEP % deg deg % % Note (at idling) 2.4% t 85C or 185F (After engine is warmed up.) 10% +10% 10% +10% 10% +10% 10% +10% 210 mmHg, 28 kPa, 8.3 inHg or 4.1 psig 600 800 rpm (After engine is warmed up.) 0 km/h or 0 MPH 13 15 deg (Ambient air temperature) 2.5 g/s 5.0 g/s or 0.31 lb/m 0.71 lb/m 2% 0.900 V 0.900 V 12 13 V 1.2 1.3 V 2.5 ms 3.5 ms 2.5 ms 3.5 ms (Atmospheric pressure) (Intake manifold absolute pressure Atmospheric pressure) 7.5 mmHg, 1 kPa, 0.3 inHg or 0.14 psi +0.0 deg 0% +28C or +82F 0% (Water temperature 90C (194F) when air conditioner is OFF) 18% 0 STEP 33% +0 deg +1 deg +0 deg +1 deg 9.4% 9.4%
EN(H6DO)(diag)-35

Contents Oil flow control solenoid valve current R Oil flow control solenoid valve current L Front oxygen (A/F) sensor current value 1 Front oxygen (A/F) sensor current value 2 Front oxygen (A/F) sensor resistance value 1 Front oxygen (A/F) sensor resistance value 2 Front oxygen (A/F) sensor output lambda 1 Front oxygen (A/F) sensor output lambda 2 A/F correction 3 A/F learning 3 SI drive mode Throttle motor duty Throttle power supply voltage Sub throttle sensor voltage Main throttle sensor voltage Sub accelerator sensor voltage Main acceleration sensor voltage Memory vehicle speed A/F correction 4 A/F learning 4 Fuel level sensor resistance Engine oil temperature Oil switching solenoid valve duty R Oil switching solenoid valve duty L Oil switching solenoid valve current R Oil switching solenoid valve current L Variable valve lift mode #1 cylinder roughness monitor #2 cylinder roughness monitor #3 cylinder roughness monitor #4 cylinder roughness monitor #5 cylinder roughness monitor #6 cylinder roughness monitor Knock sensor correction AT/MT identification Delivery (test) mode terminal System operation check mode Delivery (test) mode terminal Neutral position switch signal Idle switch signal Ignition switch signal Power steering switch signal Air conditioning switch signal Starter switch signal Front oxygen monitor 1 Front oxygen monitor 2 Knocking signal Crankshaft position sensor signal Display OCV Current R OCV Current L A/F Sensor #1 Current A/F Sensor #2 Current A/F Sensor #1 Resistance A/F Sensor #2 Resistance A/F Sensor #1 A/F Sensor #2 A/F Correction #3 A/F Learning #3 SI Drive mode Throttle Motor Duty Throttle Motor Voltage Sub-Throttle Sensor Main-Throttle Sensor Sub-Accelerator Sensor Main-Accelerator Sensor Memorized Cruise Speed A/F Correction #4 A/F Learning #4 Fuel level resistance Oil Temperature OSV Duty R OSV Duty L OSV Current R OSV Current L VVL Lift Mode Roughness Monitor #1 Roughness Monitor #2 Roughness Monitor #3 Roughness Monitor #4 Roughness Monitor #5 Roughness Monitor #6 Knocking Correction AT Vehicle ID Signal Test Mode Signal D-check Require Flag Delivery Mode Connector (Test Mode Connector) Neutral Position Switch Idle Switch Signal Ignition Switch P/S Switch Signal A/C Switch Starter Switch Front O2 #1 Rich Signal Front O2 #2 Rich Signal Knocking Signal Crankshaft Position Sig. Unit of measure mA mA mA mA : : % % % V V V V V km/h or MPH % % : C or F % % mA mA deg Note (at idling) 64 mA 64 mA 0.0 mA 0.0 mA 31 : 31 : 1.01 1.01 0% 1% 0.0% I, S or S# 20% +20% (Battery voltage) 1.4 V 1.5 V 0.62 V 0.70 V 1.0 V 1.2 V 0.9 V 1.1 V 0 km/h or 0 MPH 1% 1% 0.0% 4 96 : t 85C or 185F (After engine is warmed up.) 18.4% 18.8% 192 mA 192 mA 1 0 0 0 0 0 0 0 deg AT model OFF OFF OFF ON ON ON OFF input (When OFF) OFF input (When OFF) OFF Rich, Lean Rich, Lean None ON
EN(H6DO)(diag)-36

Contents Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Light switch signal A/C lock signal A/C middle pressure switch signal A/C compressor relay signal Pressure control solenoid valve signal Drain valve signal Variable valve lift diagnosis oil pressure switch signal 1 Variable valve lift diagnosis oil pressure switch signal 2 AT coordinate retard angle demand signal AT coordinate fuel cut demand signal Vehicle dynamics control (VDC) torque down prohibition output Vehicle dynamics control (VDC) torque down demand Torque control permission signal Electronic throttle control motor relay signal Clutch switch signal Stop light switch signal SET/COAST switch signal RESUME/ACCEL switch signal Brake switch signal Main switch signal Body integrated unit data reception Body integrated unit counter update Cruise control cancel switch signal Malfunction indicator light flag Display Camshaft Position Sig. Rear Defogger SW Blower Fan SW Light Switch A/C Lock Signal A/C Mid Pressure Switch A/C Compressor Signal PCV Solenoid Valve Vent. Solenoid Valve Eng. Oil Press. SW 1 Eng. Oil Press. SW 2 Retard Signal from AT Fuel Cut signal from AT Ban of Torque Down Request Torque Down VDC Torque Permission Signal ETC Motor Relay Clutch Switch Stop Light Switch SET/COAST SW RESUME/ACCEL SW Brake Switch Main Switch Body Int. Unit Data Body Int. Unit Count CC Cancel SW MIL On Flag Unit of measure Note (at idling) ON OFF input (When OFF) OFF input (When OFF) OFF input (When OFF) OFF OFF input (when air conditioner is OFF) OFF output (when air conditioner is OFF) OFF output (when OFF) OFF output (when OFF) ON ON None None Permission None Permission ON OFF (when clutch is OFF) OFF (when brake is OFF) OFF (when levers are not operated) OFF (when levers are not operated) OFF (when brake is OFF) OFF (when levers are not operated) ON ON OFF (when levers are not operated) Light OFF
EN(H6DO)(diag)-37


1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Current Data Display & Save}. 6) On the Current Data Display & Save display screen, select the {All Data Display}. 7) Using the scroll key, scroll the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Number of diagnosis code Condition of malfunction indicator light Monitoring test of misfire Monitoring test of misfire Monitoring test of fuel system Monitoring test of fuel system Monitoring test of comprehensive component Monitoring test of comprehensive component Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system Test of evaporative emission purge control system Secondary air system test Secondary air system test Test of air conditioning system refrigerant Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system Air fuel ratio control system for bank 1 Air fuel ratio control system for bank 2 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Display Number of Diag. Code: MI (MIL) Misfire monitoring (Supp) Misfire monitoring (Rdy) Fuel system monitoring (Supp) Fuel system monitoring (Rdy) Component monitoring (Supp) Component monitoring (Rdy) Catalyst Diagnosis (Supp) Catalyst Diagnosis (Rdy) Heated catalyst (Supp) Heated catalyst (Rdy) Evaporative purge system (Supp) Evaporative purge system (Rdy) Secondary air system (Supp) Secondary air system (Rdy) A/C system refrigerant (Supp) A/C system refrigerant (Rdy) Oxygen sensor (Supp) Oxygen sensor (Rdy) O2 Heater Diagnosis (Supp) O2 Heater Diagnosis (Rdy) EGR system (Supp) EGR system (Rdy) Fuel system for Bank 1 Fuel system for Bank 2 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Referential value (at idling) 0 OFF YES YES YES YES YES YES YES NO NO N/A YES NO NO N/A NO N/A YES NO YES NO NO N/A Cl_normal Cl_normal 21.0 91 17.2 5.5 Unit of measure % C % %
EN(H6DO)(diag)-38

Contents Short term fuel trim by front oxygen (A/F) sensor (Bank 2) Long term fuel trim by front oxygen (A/F) sensor (Bank 2) Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal #1 Cylinder ignition timing Intake air temperature signal Intake air amount Throttle position signal Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) Oxygen sensor (Bank 2 Sensor 2) A/F correction (Bank 2 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (Bank 1 Sensor 1) Oxygen sensor (Bank 1 Sensor 2) Front oxygen (A/F) sensor (Bank 2 Sensor 1) Oxygen sensor (Bank 2 Sensor 2) Elapsed time after engine start Travel distance after the malfunction indicator light illuminates A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) A/F lambda signal (Bank 2 Sensor 1) A/F sensor output signal (Bank 2 Sensor 1) Evaporative purge Fuel level signal Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure signal Atmospheric pressure signal A/F lambda signal (Bank 1 Sensor 1) A/F sensor current (Bank 1 Sensor 1) A/F lambda signal (Bank 2 Sensor 1) A/F sensor current (Bank 2 Sensor 1) Catalyst temperature #1 Catalyst temperature #2 Monitoring test of misfire Monitoring test of misfire Monitoring test of fuel system Monitoring test of fuel system Monitoring test of comprehensive component Monitoring test of comprehensive component Test of catalyst Display Short term fuel trim B2 Long term fuel trim B2 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 Oxygen sensor #22 Short term fuel trim #22 OBD System Oxygen sensor #11 Oxygen sensor #12 Oxygen sensor #21 Oxygen sensor #22 Time Since Engine Start Lighted MI lamp history A/F Sensor #11 A/F Sensor #11 A/F Sensor #21 A/F Sensor #21 Commanded Evap Purge Fuel Level Number of warm-ups Meter since DTC cleared Fuel Tank Pressure Atmosphere Pressure A/F Sensor #11 A/F Sensor #11 A/F Sensor #21 A/F Sensor #21 Catalyst Temperature #11 Catalyst Temperature #21 Misfire monitoring (Enable) Misfire monitoring (Comp) Fuel system monitoring (Enable) Fuel system monitoring (Comp) Component monitoring (Enable) Component monitoring (Comp) Catalyst Diagnosis (Enable) Referential value (at idling) 17.2 5.5 233 700 0 16.5 54 2.8 13 0.1 0.7 0.0 0.1 0.7 0.0 OBD/OBD2 Support Support Support Support 1.001 2.805 1.001 2.805 0 8.8 Atmospheric pressure 0.999 0.02 0.999 0.02 YES NO YES NO YES NO YES Unit of measure % % mmHg rpm km/h C g/s % V % V % sec km V V % % km mmHg mmHg mA mA C C
EN(H6DO)(diag)-39

Contents Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system Test of evaporative emission purge control system Secondary air system test Secondary air system test Test of air conditioning system refrigerant Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light lit Elapsed time after DTC clear Fuel used Relative acceleration opening angle Display Catalyst Diagnosis (Comp) Heated catalyst (Enable) Heated catalyst (Comp) Evaporative purge system (Enable) Evaporative purge system (Comp) Secondary air system (Enable) Secondary air system (Comp) A/C system refrigerant (Enable) A/C system refrigerant (Comp) Oxygen sensor (Enable) Oxygen sensor (Comp) O2 Heater Diagnosis (Enable) O2 Heater Diagnosis (Comp) EGR system (Enable) EGR system (Comp) Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. Time while MIL lighted Time since DTC cleared Type of fuel Relative Accelera. Pos. Referential value (at idling) NO N/A N/A NO NO N/A N/A N/A N/A YES NO YES NO N/A N/A 13.789 22 0.976 2 Ambient air temperature 32 13 13 0 GAS 0 Unit of measure V % % C % % % % min min %
EN(H6DO)(diag)-40


Contents DTC of freeze frame data Air fuel ratio control system for bank 1 Air fuel ratio control system for bank 2 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Short term fuel trim by front oxygen (A/F) sensor (Bank 2) Long term fuel trim by front oxygen (A/F) sensor (Bank 2) Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing adv. #1 Intake air temperature Amount of intake air Throttle valve angle Oxygen sensor #12 A/F correction value #12 Oxygen sensor #22 A/F correction value #22 On-board diagnostic system Oxygen sensor #11 Oxygen sensor #12 Oxygen sensor #21 Oxygen sensor #22 Elapsed time after engine start Target EGR EGR deviation Evaporative purge Fuel level signal Fuel tank pressure signal Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Display Freeze frame data Fuel system for Bank 1 Fuel system for Bank 2 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Short term fuel trim B2 Long term fuel trim B2 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 Oxygen sensor #22 Short term fuel trim #22 OBD System Oxygen sensor #11 Oxygen sensor #12 Oxygen sensor #21 Oxygen sensor #22 Time Since Engine Start Commanded EGR EGR Error Commanded Evap Purge Fuel Level Fuel Tank Pressure Atmosphere Pressure Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. Unit of measure % C or F % % % % mmHg, kPa, inHg or psig rpm km/h or MPH C or F g/s % V % V % sec % % % % mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig V % % C or F % % % %
EN(H6DO)(diag)-41

5. V.I.N. REGISTRATION
EN(H6DO)(diag)-42


A: OPERATION
1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display}. 5) On the Diagnostic Code(s) Display display screen, select the {Temporary Diagnostic Code(s)} or {Memorized Diagnostic Code(s)}. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)-81, List of Diagnostic Trouble Code (DTC).>

Refer to the data denoting emission-related powertrain DTC. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)-81, List of Diagnostic Trouble Code (DTC).> NOTE: Refer to the general scan tool manufacturers operation manual to access powertrain DTC (MODE $03).

1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Diagnostic Code(s) Display}. 6) Make sure DTC is shown on the screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)-81, List of Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-43
Inspection Mode
11.Inspection Mode
A: PROCEDURE
Perform the diagnosis shown in the following DTC table. When performing the diagnosis not listed in List of Diagnostic Trouble Code (DTC), refer to the item on the drive cycle. <Ref. to EN(H6DO)(diag)-48, Drive Cycle.>
DTC P0011 P0016 P0018 P0021 P0031 P0032 P0037 P0038 P0051 P0052 P0057 P0058 P0077 P0083 P0102 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0137 P0138 P0140 P0151 P0152 P0157 P0158 P0160 P0182 P0183 P0197 P0198 P0222 P0223 P0230 P0327 P0328 P0332 P0333 Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank1) Crankshaft Position - Camshaft Position Correlation (Bank2) Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) HO2S Heater Control Circuit Low (Bank 2 Sensor 1) HO2S Heater Control Circuit High (Bank 2 Sensor 1) HO2S Heater Control Circuit Low (Bank 2 Sensor 2) HO2S Heater Control Circuit High (Bank 2 Sensor 2) Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit High (Bank 2) Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch A Circuit Low Throttle/Pedal Position Sensor/Switch A Circuit High O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1) O2 Sensor Circuit High Voltage (Bank 2 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2) O2 Sensor Circuit High Voltage (Bank 2 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2) Fuel Temperature Sensor A Circuit Low Input Fuel Temperature Sensor A Circuit High Input Engine Oil Temperature Sensor Low Engine Oil Temperature Sensor High Throttle/Pedal Position Sensor/Switch B Circuit Low Throttle/Pedal Position Sensor/Switch B Circuit High Fuel Pump Primary Circuit Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) Knock Sensor 2 Circuit Low (Bank 2) Knock Sensor 2 Circuit High (Bank 2) Condition
EN(H6DO)(diag)-44
Inspection Mode
DTC P0335 P0336 P0340 P0345 P0447 P0448 P0452 P0453 P0458 P0462 P0463 P0500 P0512 P0513 P0600 P0604 P0605 P0607 P0638 P0700 P1152 P1153 P1154 P1155 P1160 P1400 P1420 P1560 P1570 P1571 P1572 P1574 P1576 P1577 P1578 P2088 P2089 P2092 P2093 P2101 P2102 P2109 P2122 P2123 P2127 P2128 P2135 P2138 P2227 P2228 P2229 Item Crankshaft Position Sensor A Circuit Crankshaft Position Sensor A Circuit Range/Performance Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor) Camshaft Position Sensor A Circuit (Bank 2) Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission System Purge Control Valve Circuit Low Fuel Level Sensor A Circuit Low Fuel Level Sensor A Circuit High Vehicle Speed Sensor A Starter Request Circuit Incorrect Immobilizer Key Serial Communication Link Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (MIL Request) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (Low) (Bank 2 Sensor 1) O2 Sensor Circuit Range/Performance (High) (Bank 2 Sensor 1) Return Spring Failure Fuel Tank Pressure Control Solenoid Valve Circuit Low Fuel Tank Pressure Control Sol. Valve Circuit High Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure (Except Antenna Circuit) Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Intake Camshaft Position Actuator Control Circuit Low (Bank 1) Intake Camshaft Position Actuator Control Circuit High (Bank 1) Intake Camshaft Position Actuator Control Circuit Low (Bank 2) Intake Camshaft Position Actuator Control Circuit High (Bank 2) Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle/Pedal Position Sensor A Minimum Stop Performance Throttle/Pedal Position Sensor/Switch D Circuit Low Input Throttle/Pedal Position Sensor/Switch D Circuit High Input Throttle/Pedal Position Sensor/Switch E Circuit Low Input Throttle/Pedal Position Sensor/Switch E Circuit High Input Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation Barometric Pressure Circuit Range/Performance Barometric Pressure Circuit Low Barometric Pressure Circuit High Condition
EN(H6DO)(diag)-45
Inspection Mode

1) Check battery voltage is 12 V or more and fuel remains half [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)]. 2) Lift up the vehicle using a garage jack and place it on rigid racks, or drive the vehicle onto free rollers. WARNING: Before lifting up the vehicle, ensure parking brakes are applied. Do not use a pantograph jack in place of a rigid rack. Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front wheels. Before rotating the wheels, make sure that there is no one in front of the vehicle. Besides while the wheels are rotating, make sure that no one approaches the vehicle front side. Make sure that there is nothing around the wheels. For AWD model, pay special attention to all four wheels. While servicing, do not depress or release the clutch pedal or accelerator pedal quickly regardless of the engine speed. Quick operation may cause the vehicle to drop off the free roller. To prevent the vehicle from slipping due to vibration, do not place anything between rigid rack and the vehicle.

1) Check that no DTC remains after clearing memory. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> 2) Warm up the engine. 3) Prepare the Subaru Select Monitor kit. <Ref. to EN(H6DO)(diag)-7, PREPARATION TOOL, General Description.>
EN-05692
(A)
PI-00201 (A)
(B)
EN-00041 EN-02533
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool.
EN(H6DO)(diag)-46
Inspection Mode
9) Start the PC. 10) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 11) On the Main Menu display screen, select the {Each System Check}. 12) On the System Selection Menu display screen, select the {Engine Control System}. 13) Click the [OK] button after the information of engine type has been displayed. 14) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure}. 15) When the Perform Inspection (Dealer Check) Mode? is shown on the screen, click the [Next] button. 16) Perform subsequent procedures as instructed on the display screen. If trouble still remains in the memory, the corresponding DTC appears on the display screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)-81, List of Diagnostic Trouble Code (DTC).> Release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system. <Ref. to ABS(diag)-20, Clear Memory Mode.>
EN-02533
5) Start the engine. NOTE: Ensure the selector lever is placed in P range before starting. 6) Turn the neutral position switch to ON using select lever. 7) Depress the brake pedal to turn the brake switch ON. 8) Keep the engine speed in 2,500 3,000 rpm range for 40 seconds. 9) Place the select lever in D range and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: For AWD model, release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of the self-diagnosis system. <Ref. to ABS(diag)-20, Clear Memory Mode.> 10) Using the general scan tool, check DTC and record the result(s). NOTE: For detailed operation procedures, refer to the general scan tool operation manual. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)-81, List of Diagnostic Trouble Code (DTC).>

1) After performing the diagnostics and clearing the memory, check that no DTC remains. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> 2) Warm up the engine. 3) Connect the delivery (test) mode connector (A) located under the glove box.
(A)
PI-00201
EN(H6DO)(diag)-47
Drive Cycle
12.Drive Cycle
A: PROCEDURE

1) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)]. 2) After performing the diagnostics and clearing the memory, check that no DTC remains. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> 3) Disconnect the delivery (test) mode connector. NOTE: Except for the water temperature specified at starting, be sure to carry out the diagnosis after the engine is warmed up. Perform the diagnosis twice if the DTC marked with *. After completing the first diagnosis, stop the engine and perform second diagnosis in same condition.
2. DRIVE CYCLE A DRIVE THE VEHICLE WITH 80 KM/H (50 MPH) FOR 20 MINUTES, AND THEN IDLE THE ENGINE FOR A MINUTE
DTC *P0125 *P0126 *P0128 *P0133 *P0153 *P0171 *P0172 *P0174 *P0175 *P0196 *P0301 *P0302 *P0303 *P0304 *P0305 *P0306 *P0420 *P0442 *P0451 *P0456 *P0457 *P0464 P1443 *P2096 *P2097 *P2098 *P2099 P2103 Item Insufficient Coolant Temperature for Closed Loop Fuel Control Insufficient Engine Coolant Temperature For Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) System Too Lean (Bank 1) System Too Rich (Bank 1) System Too Lean (Bank 2) System Too Rich (Bank 2) Engine Oil Temperature Sensor Circuit Range/Performance Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Cylinder 5 Misfire Detected Cylinder 6 Misfire Detected Catalyst System Efficiency below Threshold (Bank 1) Evaporative Emission Control System Leak Detected (Small Leak) Evaporative Emission Control System Pressure Sensor Evaporative Emission Control System Leak Detected (Very Small Leak) Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Fuel Level Sensor Circuit Intermittent Vent Control Solenoid Valve Function Problem Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Post Catalyst Fuel Trim System Too Lean Bank 2 Post Catalyst Fuel Trim System Too Rich Bank 2 Throttle Actuator Control Motor Circuit High Condition Engine coolant temperature at engine start is less than 20C (68F). Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Engine coolant temperature at engine start is less than 25C (77F). Engine coolant temperature at engine start is less than 25C (77F). Engine coolant temperature at engine start is less than 25C (77F). Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well.
EN(H6DO)(diag)-48
Drive Cycle

NOTE: Drive the vehicle at 10 km/h (6 MPH) or faster before diagnosis.
DTC *P0171 *P0172 *P0174 *P0175 *P0301 *P0302 *P0303 *P0304 *P0305 *P0306 *P0459 *P0506 *P0507 *P2096 *P2097 *P2098 *P2099 P2103 Condition System Too Lean (Bank 1) Complete diagnosis with drive cycle A or C as well. System Too Rich (Bank 1) Complete diagnosis with drive cycle A or C as well. System Too Lean (Bank 2) Complete diagnosis with drive cycle A or C as well. System Too Rich (Bank 2) Complete diagnosis with drive cycle A or C as well. Cylinder 1 Misfire Detected Complete diagnosis with drive cycle A or C as well. Cylinder 2 Misfire Detected Complete diagnosis with drive cycle A or C as well. Cylinder 3 Misfire Detected Complete diagnosis with drive cycle A or C as well. Cylinder 4 Misfire Detected Complete diagnosis with drive cycle A or C as well. Cylinder 5 Misfire Detected Complete diagnosis with drive cycle A or C as well. Cylinder 6 Misfire Detected Complete diagnosis with drive cycle A or C as well. Evaporative Emission System Purge Control Valve Circuit High Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Post Catalyst Fuel Trim System Too Lean (Bank 1) Complete diagnosis with drive cycle A or C as well. Post Catalyst Fuel Trim System Too Rich (Bank 1) Complete diagnosis with drive cycle A or C as well. Post Catalyst Fuel Trim System Too Lean Bank 2 Complete diagnosis with drive cycle A or C as well. Post Catalyst Fuel Trim System Too Rich Bank 2 Complete diagnosis with drive cycle A or C as well. Throttle Actuator Control Motor Circuit High Complete diagnosis with drive cycle A or C as well. Item

(H)
(C) 97 (60) (D) 64 (40) (F) (G)
(B)
(E)
(A) 0 50 100 150 (I) EN-00842
(A) (B) (C)
Idle the engine for 10 seconds or more. Accelerate the vehicle to 97 km/h (60 MPH) within 20 seconds. Drive the vehicle at 97 km/h (60 MPH) for 20 seconds.
(D) (E) (F)
Decelerate the vehicle to 64 km/h (40 MPH) with throttle fully closed. Drive the vehicle at 64 km/h (40 MPH) for 20 seconds. Accelerate the vehicle to 97 km/h (60 MPH) within 10 seconds.
(G) (H) (I)
Stop the vehicle with throttle fully closed. Vehicle speed km/h (MPH) Sec.
EN(H6DO)(diag)-49
Drive Cycle
DTC P0026 P0028 *P0030 *P0050 *P0068 P0076 P0082 *P0101 P0134 *P0139 P0154 *P0159 *P0171 *P0172 *P0174 *P0175 *P0301 *P0302 *P0303 *P0304 *P0305 *P0306 *P0400 P1492 P1493 P1494 P1495 P1496 P1497 P1498 P1499 *P2096 *P2097 *P2098 *P2099 P2103 Item Intake Valve Control Solenoid Circuit Range/Performance (Bank 1) Intake Valve Control Solenoid Circuit Range/Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit (Bank 2 Sensor 1) MAP/MAF - Throttle Position Correlation Intake Valve Control Solenoid Circuit Low (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Mass or Volume Air Flow Circuit Range/Performance O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1) O2 Sensor Circuit Slow Response (Bank 2 Sensor 2) System Too Lean (Bank 1) System Too Rich (Bank 1) System Too Lean (Bank 2) System Too Rich (Bank 2) Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Cylinder 5 Misfire Detected Cylinder 6 Misfire Detected Exhaust Gas Recirculation Flow EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input) Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Post Catalyst Fuel Trim System Too Lean Bank 2 Post Catalyst Fuel Trim System Too Rich Bank 2 Throttle Actuator Control Motor Circuit High Condition Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well.
5. DRIVE CYCLE D
Drift Diagnosis 1) Make sure that the engine coolant temperature at engine starting is less than 30C (86F). 2) Make sure that fuel remains 10 2 (2.6 US gal, 2.2 Imp gal) or more and the battery voltage is 10.9 V or more. 3) Start the engine, and check that the engine coolant temperature increases by 10C (50F) or more, and reaches 75C (167F) or more, when the engine is warmed up. 4) After the engine has reached the state of procedure 3), idle the engine for 120 seconds or more.
EN(H6DO)(diag)-50
Drive Cycle
Stuck Diagnosis 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> 3) Drive for approximately 50 2 (13.2 US gal, 11 Imp gal) of fuel. NOTE: It is acceptable to drive the vehicle intermittently. Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
6. DRIVE CYCLE E
1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> 3) Drive for approximately 30 2 (7.9 US gal, 6.6 Imp gal) of fuel. NOTE: It is acceptable to drive the vehicle intermittently. Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
7. DRIVE CYCLE F
1) Make sure that the engine coolant temperature at engine starting is less than 30C (86F). 2) Start the engine, and warm it up until engine coolant temperature reaches to 95C (203F) or more. 3) Idle the engine for 10 minutes or more in the condition of step 2. NOTE: Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)
DTC *P0111 Item Motor/Motor Relay Malfunction Condition
8. DRIVE CYCLE H
1) Perform the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> 2) With the ignition switch ON, read the engine coolant temperature, intake air temperature and fuel temperature. <Ref. to EN(H6DO)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> 3) If the values from step 2) satisfy the following two conditions, start the engine. Condition: |Engine coolant temperature intake air temperature | d 5C (41F) |Engine coolant temperature fuel temperature | d 2C (36F) NOTE: If the conditions are not satisfied, turn the ignition switch to OFF and wait until the parameters are satisfied. Start AT vehicles in the P range, and MT vehicles in the neutral position. 4) Idle the engine for 1 minute under the conditions in step 3).
DTC
*P1602
Condition
EN(H6DO)(diag)-51
Clear Memory Mode


A: OPERATION

For procedures clearing memory using the general scan tool, refer to the general scan tool operation manual. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. For this reason, start the engine after 10 seconds or more have elapsed since the ignition switch was turned to ON.


1) On the Main Menu display screen, select the {Each System Check}. 2) On the System Selection Menu display screen, select the {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On the Engine Diagnosis display screen, select the {OBD System}. 5) On the OBD Menu display screen, select the {Clear Diagnostic Code}. 6) When the Clear Diagnostic Code? is shown on the screen, click the [Yes] button. 7) When Done and Turn off the ignition switch. are shown on the display screen, click the [OK] button. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine. For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H6DO)(diag)-52


A: OPERATION
EN-05692
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 7) Start the PC. 8) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 9) On the Main Menu display screen, select the {Each System Check}. 10) On the System Selection Menu display screen, select the {Engine Control System}. 11) Click the [OK] button after the information of engine type has been displayed. 12) On the Engine Diagnosis display screen, select the {System Operation Check Mode}. 13) On the System Operation Check Mode display, select the {Actuator ON/OFF Operation}. 14) Select the desired actuator on the Actuator ON/OFF Operation display screen and click the [Next] button. 15) Clicking the [End] button completes the compulsory valve operation check mode. The display will then return to the Actuator ON/OFF Operation screen. A list of the support data is shown in the following table.
Description Compulsory fuel pump relay operation check Compulsory purge control solenoid valve operation check Compulsory radiator fan relay operation check Compulsory air conditioning relay operation check Display Fuel Pump Relay CPC Solenoid Valve Radiator Fan Relay A/C Compressor Relay

(A) EN-02424
Display EGR Solenoid Valve ASV Solenoid Valve PCV Solenoid Valve Vent. Solenoid Valve FICD Solenoid Pressure Switching Sol.1 Pressure Switching Sol.2 AAI Solenoid Valve Tank Sensor Cntl Valve Turbocharger Wastegate Solenoid EXH. Bypass Control Permit Flag Secondary Air Combi Valve 1
EN-02533
EN(H6DO)(diag)-53


A: OPERATION
11) On the Engine Diagnosis display screen, select the {System Operation Check Mode}. 12) The following items are displayed on the monitor.
Display Actuator ON/OFF Operation Immobilizer System Fuel Pump Control Fixed Idle Ignition Timing Idle Speed Control Injector Control EGR Valve Control
1. FUEL PUMP CONTROL (OFF OPERATION)

EN-05692
CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fuel Pump Control}. 2) On the Fuel Pump Control display screen, select the {OFF Drive}. 3) On the Start the Engine display screen, start the engine and click the [OK] button. 4) On the OFF Drive display screen, click the [Execution] button and execute the OFF drive. 5) Click the [Cancel] button to stop the OFF drive. 6) Click the [ Exit] button to end the OFF drive. The screen will return to the Fuel Pump Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
2. FUEL PUMP CONTROL (ON/OFF OPERATION)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fuel Pump Control}. 2) On the Fuel Pump Control display screen, select the {ON/OFF Dr.}. 3) On the Turn Ignition Switch ON with Engine OFF display screen, turn the ignition switch to ON and click the [OK] button. 4) On the ON/OFF Dr. display screen, click the [Execution] button and execute the ON/OFF drive. 5) Click the [Cancel] button to stop the ON/OFF drive.
EN-02097
CAUTION: Do not connect the scan tools except for Subaru Select Monitor and general scan tool. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 8) On the Main Menu display screen, select the {Each System Check}. 9) On the System Selection Menu display screen, select the {Engine Control System}. 10) Click the [OK] button after the information of engine type has been displayed.
EN(H6DO)(diag)-54

6) Click the [ Exit] button to end the ON/OFF drive. The screen will return to the Fuel Pump Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
5. INJECTOR CONTROL (INJECTION STOP MODE)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Injector Control}. 2) On the Injector Control display screen, select the {Injection Stop Mode}. 3) On the Injection Stop Mode display screen, select the fuel injector to be stopped. 4) On the Start the Engine display screen, start the engine and click the [OK] button. 5) On the Fuel Injector # display screen, click the [Execution] button and execute the injection stop mode. 6) Click the [Cancel] button to stop the injection stop mode. 7) Click the [ Exit] button to return the Injection Stop Mode display screen. 8) On the Injection Stop Mode display screen, click the [Return] button to end the Injection Stop Mode. The screen will return to the Injector Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Fixed Idle Ignition Timing}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) On the Fixed Idle Ignition Timing display screen, click the [Execution] button and execute the idling ignition timing fixed. 4) Click the [Cancel] button to stop the idling ignition timing fixed. 5) Click the [ Exit] button to end the idling ignition timing fixed. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Idle Speed Control}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) In the Idle Speed Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in a range between 500 rpm 2,000 rpm, in increments of 50 rpm. However, the engine speed that can actually be controlled will vary depending on the vehicle. 4) Click the [Cancel] button to stop the idle speed control. 5) Click the [ Exit] button to end the idle speed control. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
6. INJECTOR CONTROL (INJECTION QUANTITY CONTROL)

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {Injector Control}. 2) On the Injector Control display screen, select the {Injection Quantity Control}. 3) On the Start the Engine display screen, start the engine and click the [OK] button. 4) In the Injection Quantity Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in a range between 0 20%, in increments of 1%. 5) Click the [Cancel] button to stop the injection quantity control. 6) Click the [ Exit] button to end the injection quantity control. The screen will return to the Injector Control screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H6DO)(diag)-55

7. EGR VALVE CONTROL

CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.> 1) On the System Operation Check Mode display screen, select the {EGR Valve Control}. 2) On the Start the Engine display screen, start the engine and click the [OK] button. 3) In the EGR Valve Control display screen, click the [ ] button or the [ ] button to change the setting values, then click the [OK] button. Setting is possible in increments of 1 STEP. However, the STEP number that can actually be controlled will vary depending on the vehicle. 4) Click the [Cancel] button to stop the EGR valve control. 5) Click the [ Exit] button to end the EGR valve control. The display will then return to the System Operation Check Mode screen. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
EN(H6DO)(diag)-56


A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H6DO)(diag)-58, ACTIVATION OF MALFUNCTION INDICATOR LIGHT, Malfunction Indicator Light.> p 2. Malfunction indicator light does not come on. <Ref. to EN(H6DO)(diag)-59, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.> p 3. Malfunction indicator light does not go off. <Ref. to EN(H6DO)(diag)-61, MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF, Malfunction Indicator Light.> p 4. Malfunction indicator light does not blink. <Ref. to EN(H6DO)(diag)-62, MALFUNCTION INDICATOR LIGHT DOES NOT BLINK, Malfunction Indicator Light.> p 5. Malfunction indicator light remains blinking. <Ref. to EN(H6DO)(diag)-64, MALFUNCTION INDICATOR LIGHT REMAINS BLINKING, Malfunction Indicator Light.>
EN(H6DO)(diag)-57


1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit. <Ref. to EN(H6DO)(diag)-59, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>
(1) (2) (4)
(3)
CHECK ENGINE
EN-01681 (A) EN-03112
(1) (3) (4) (2) (3) (4) (5) (6) EN-01679
(1) (2) (3) (4)
(1) (2) (3) (4) (5) (6)
No faulty Trouble occurs ON OFF Ignition switch ON Engine start
EN(H6DO)(diag)-58


B72 No.5 1
BATTERY
E
3
COMBINATION METER i10 16 i3 8 B38 B136 ECM 11
B72
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
i10 1 2 3 4 5 11 12 13 14 15 16 6 7 8 9 10 17 18 19 20 21 22
B38
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05649
EN(H6DO)(diag)-59

Step Check Yes CHECK OUTPUT SIGNAL OF ECM. Is the voltage 10 V or more? Go to step 5. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 11 (+) Chassis ground (): CHECK HARNESS BETWEEN COMBINAIs the resistance less than 1 :? Go to step 3. TION METER AND ECM CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the combination meter. <Ref. to IDI-22, Combination Meter.> 3) Disconnect the connector from ECM and combination meter. 4) Measure the resistance of harness between ECM connector and combination meter connector. Connector & terminal (B136) No. 11 (i10) No. 16: Is there poor contact in combi- Repair the poor nation meter connector? contact of combination meter connector. CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more? Replace the comTION METER AND IGNITION SWITCH CONbination meter NECTOR. board. <Ref. to IDI1) Turn the ignition switch to ON. 22, Combination 2) Measure the voltage between combination Meter.> meter connector and chassis ground. Connector & terminal (i10) No. 3 (+) Chassis ground (): CHECK POOR CONTACT. Check for poor contact of combination meter connector. No Go to step 2.
CHECK POOR CONTACT. Check for poor connection by shaking or pulling ECM connector and harness. CHECK ECM CONNECTOR. Check the connection of ECM connector.
Does the malfunction indicator Repair the poor light illuminate? contact of ECM connector. Is the ECM connector correctly Replace the ECM. Repair the connecconnected? <Ref. to tion of ECM conFU(H6DO)-38, nector. Engine Control Module (ECM).>
EN(H6DO)(diag)-60


B72 No.5 1
BATTERY
E
3
COMBINATION METER i10 16 i3 8 B38 B136 ECM 11
B72
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
i10 1 2 3 4 5 11 12 13 14 15 16 6 7 8 9 10 17 18 19 20 21 22
B38
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
EN-05649
Step CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Turn the ignition switch to ON.
Check Yes Does the malfunction indicator Repair the short light illuminate? circuit of harness between combination meter and ECM connector.
No Replace the ECM. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
EN(H6DO)(diag)-61


COMBINATION METER i10 16 : TERMINAL No. OPTIONAL ARRANGEMENT
*
DELIVERY (TEST) MODE CONNECTOR 1 B75 i3 1 B76
B122
* *
8 B38 C11
B27
B: B135
C: B136
ECM
B75 1 2
B72
i10 1 2 3 4 5 11 12 13 14 15 16 6 7 8 9 10 17 18 19 20 21 22
C6
B38
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B:
B135
C:
B136 5 6 14 15 16 25 26 27 33 34 35
B122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8
EN-05650
EN(H6DO)(diag)-62

Step Check Yes CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 2. CATOR LIGHT. light illuminate? 1) Turn the ignition switch to OFF. 2) Disconnect the delivery (test) mode connector. 3) Turn the ignition switch to ON. (engine OFF) No Repair the malfunction indicator light circuit. <Ref. to EN(H6DO)(diag)59, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.> Does the malfunction indicator Repair the ground Go to step 3. CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR. light illuminate? short circuit of har1) Turn the ignition switch to OFF. ness between 2) Disconnect the connectors from ECM. combination meter 3) Turn the ignition switch to ON. and ECM connector. CHECK HARNESS BETWEEN DELIVERY Is the resistance less than 1 :? Go to step 4. Repair the harness (TEST) MODE CONNECTOR AND ECM CONand connector. NECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM. the following item: 3) Measure the resistance of harness between Open circuit of delivery (test) mode connector and ECM conharness between nector. ECM and delivery Connector & terminal (test) mode con(B76) No. 1 (B136) No. 6 nector (B75) No. 1 (B135) No. 27 Poor contact in joint connector CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the ECM. Check for poor contact of the ECM connector. connector? contact of ECM <Ref. to connector. FU(H6DO)-38, Engine Control Module (ECM).>
EN(H6DO)(diag)-63


COMBINATION METER i10 16 : TERMINAL No. OPTIONAL ARRANGEMENT
*
DELIVERY (TEST) MODE CONNECTOR 1 B75 i3 1 B76
B122
* *
8 B38 C11
B27
B: B135
C: B136
ECM
B75 1 2
B72
i10 1 2 3 4 5 11 12 13 14 15 16 6 7 8 9 10 17 18 19 20 21 22
C6
B38
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B:
B135
C:
B136 5 6 14 15 16 25 26 27 33 34 35
B122
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8
EN-05650
EN(H6DO)(diag)-64

Step Check Yes CHECK DELIVERY (TEST) MODE CONNEC- Does the malfunction indicator Go to step 2. TOR. light blink? 1) Disconnect the delivery (test) mode connector. 2) Turn the ignition switch to ON. No System is normal. NOTE: Malfunction indicator light blinks when delivery (test) mode connector is connected. CHECK HARNESS BETWEEN ECM CONReplace the ECM. Is the resistance less than 5 :? Repair the short NECTOR AND CHASSIS GROUND TERMIcircuit to ground in <Ref. to NAL. harness between FU(H6DO)-38, 1) Turn the ignition switch to OFF. ECM and delivery Engine Control 2) Disconnect the connectors from ECM. (test) mode conModule (ECM).> 3) Measure the resistance of harness between nector. ECM connector and chassis ground. Connector & terminal (B135) No. 27 Chassis ground:
EN(H6DO)(diag)-65


A: PROCEDURE
1. Check of the fuel amount p 2. Inspection of starter motor circuit. <Ref. to EN(H6DO)(diag)-67, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> p 3. Inspection of ECM power supply and ground line. <Ref. to EN(H6DO)(diag)-71, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> p 4. Inspection of ignition control system. <Ref. to EN(H6DO)(diag)-73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> p 5. Inspection of fuel pump circuit. <Ref. to EN(H6DO)(diag)-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.> p 6. Inspection of fuel injector circuit. <Ref. to EN(H6DO)(diag)-77, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(H6DO)(diag)-66


CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
IGNITION SWITCH B72 BATTERY SBF-6 3 2 MAIN SBF
No.21
11
INHIBITOR RELAY B226 10 7
STARTER RELAY B225 16 14 STARTER MOTOR
TCM
11 B55 31 32 20 B14 ECM B136
15
13
B226
B72 1 2 3 4 5 6
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 3 5 7 2 4 6 8 25 26 27 28 9 10 11 12
B225 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4
7 8 9 10 5 11 6
EN-05651
EN(H6DO)(diag)-67

Step Check CHECK BATTERY. Is the voltage 12 V or more? Check the battery voltage. CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate? CHECK DTC. Is DTC displayed? <Ref. to EN(H6DO)(diag)-43, OPERATION, Read Diagnostic Trouble Code (DTC).> Yes Go to step 2. Go to step 3. Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> No Charge or replace the battery. Go to step 4. The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 5.
1 2 3
CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage 10 V or more? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from starter motor. 3) Place the select lever in P range or N range. 4) Turn the ignition switch to START. 5) Measure the voltage between the starter motor connector and the engine ground. Connector & terminal (B14) No. 1 (+) Engine ground (): CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage 10 V or more? TOR. 1) Place the select lever in P range or N range. 2) Turn the ignition switch to START. 3) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B225) No. 14 (+) Chassis ground (): CHECK HARNESS BETWEEN BATTERY Is the voltage 10 V or more? AND IGNITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition switch. 3) Measure the voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 3 (+) Chassis ground ():
Repair the open circuit of the harness between starter relay connector and starter motor.
Go to step 6.
Go to step 7.
CHECK IGNITION SWITCH. Is the resistance less than 1 :? Go to step 8. Measure the resistance between ignition switch terminals after turning the ignition switch to START position. Terminals No. 2 No. 3:
EN(H6DO)(diag)-68

Step CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Remove the starter relay. 2) Connect the connector to ignition switch. 3) Turn the ignition switch to START. 4) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B225) No. 13 (+) Chassis ground (): CHECK STARTER RELAY. 1) Connect the battery to starter relay terminals No. 15 and No. 16. 2) Measure the resistance between starter relay terminals. Terminals No. 13 No. 14: CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and starter relay connector. Connector & terminal (B136) No. 20 (B225) No. 16: CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Connect the connector to ECM. 2) Place the select lever in P range or N range. 3) Turn the ignition switch to START. 4) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B225) No. 15 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND INHIBITOR RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the inhibitor relay connector. 3) Measure the resistance of harness between ECM and inhibitor relay connector. Connector & terminal (B136) No. 31 (B226) No. 7: (B136) No. 32 (B226) No. 10: Check Is the voltage 10 V or more? Yes Go to step 9. No Repair the open circuit of harness between starter relay connector and ignition switch connector.
Replace the starter relay.
10
11
Go to step 12.
Go to step 13.
12
13
Is the resistance less than 1 :? Check the ECM power supply and ground line. <Ref. to EN(H6DO)(diag)71, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> CHECK INPUT VOLTAGE OF INHIBITOR RE- Is the voltage 10 V or more? Go to step 14. LAY. 1) Turn the ignition switch to OFF. 2) Disconnect the inhibitor relay connector. 3) Turn the ignition switch to START. 4) Measure the voltage between inhibitor relay connector and chassis ground. Connector & terminal (B226) No. 9 (+) Chassis ground (): (B226) No. 11 (+) Chassis ground ():
Repair the open circuit of harness between ECM and inhibitor relay connector.
Check the following item and repair if necessary. Blown out of fuse Open or ground short circuit of harness between ignition switch connector and inhibitor relay connector
EN(H6DO)(diag)-69

Step Check CHECK INHIBITOR RELAY. Is the resistance less than 1 :? 1) Connect the battery to inhibitor relay terminals No. 7 and No. 9. 2) Measure the resistance between inhibitor relay terminals. Terminals No. 10 No. 11: CHECK HARNESS BETWEEN INHIBITOR Is the resistance less than 1 :? RELAY CONNECTOR AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between inhibitor relay connector and starter relay connector. Connector & terminal (B226) No. 10 (B225) No. 15: Yes Go to step 15. No Replace the inhibitor relay.
14
15
Repair the open circuit of harness between TCM and inhibitor relay connector.
Repair the open circuit of harness between inhibitor relay connector and starter relay connector.
EN(H6DO)(diag)-70

MAIN RELAY 3 5 6 4 2 1 B47 No. 12 1 C23 B2 A7 B5 B19 3 TO OXYGEN SENSOR SBF-5 SBF-7 No. 13 IGNITION SWITCH SBF-6 MAIN SBF
B72
BATTERY
A: B134 B: B135 C: B136 D: B137 D3 A3 D2 D1 D7 A5 ECM
B21 37 35 34 52 36 E2
B21 B72 B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47 1 8 9 18 19 28 29
A: 2 10 20 30
B134
B:
B135
1 2 3 4 5 6
3 4 5 6 7 11 12 13 14 15 17 16 21 22 23 24 25 27 26 34 33 31 32 B136 5 6 16 14 15 27 25 26 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137
C:
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06864
EN(H6DO)(diag)-71

Step Check Yes CHECK MAIN RELAY. Is the resistance less than 1 :? Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the main relay. 3) Connect the battery to main relay terminals No. 1 and No. 2. 4) Measure the resistance between main relay terminals. Terminals No. 3 No. 5: No. 4 No. 6: CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? Go to step 3. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM connector and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 5 (+) Chassis ground (): (B135) No. 19 (+) Chassis ground (): CHECK INPUT VOLTAGE OF MAIN RELAY. Measure the voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 2 (+) Chassis ground (): (B47) No. 5 (+) Chassis ground (): (B47) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND MAIN RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between ECM connector and fuel pump relay connector. Connector & terminal (B136) No. 23 (B47) No. 1: CHECK INPUT VOLTAGE OF ECM. 1) Install the main relay. 2) Connect the connector to ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): Is the voltage 10 V or more? Go to step 4. No Replace the main relay. <Ref. to FU(H6DO)-39, Main Relay.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Repair the open or ground short circuit of harness of power supply circuit.
Go to step 5.
Repair the open circuit of harness between ECM connector and main relay connector.
Check ignition control system. <Ref. to EN(H6DO)(diag)73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM connector and fuel injector connector Poor contact of main relay connector
EN(H6DO)(diag)-72


B225 RELAY BLOCK 2 1 4 B327 MAIN RELAY 2 SBF-7 6 BATTERY
B137
ECM
E
18 21 19 20 6 26 22 23 B21 18 E2 E45 3 1 2 3 1 2
14
15
49
13
54
16
E31 2 2 3 1 3 1
E32 2 3 1
E33 3 1 2
E34
17
E46
IGNITION COIL No. 1
IGNITION COIL No. 2
IGNITION COIL No. 3 B225
IGNITION COIL No. 4
IGNITION COIL No. 5
IGNITION COIL No. 6
E31 E32 E33 1 2 3
E34 E45 E46
B327 1 3 5 2 4 6
1 3 5 7 2 4 6 8 25 26 27 28 9 10 11 12
B21 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
13 14 15 16 29 30 31 32
EN-06865
EN(H6DO)(diag)-73

Step CHECK SPARK PLUG CONDITION. 1) Remove the spark plug. <Ref. to IG(H6DO)4, REMOVAL, Spark Plug.> 2) Check the spark plug condition. <Ref. to IG(H6DO)-5, INSPECTION, Spark Plug.> CHECK IGNITION SYSTEM FOR SPARKS. 1) Connect the spark plug to ignition coil. 2) Release the fuel pressure. <Ref. to FU(H6DO)-43, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.> 3) Contact the spark plugs thread portion to the engine. 4) While opening the throttle valve fully, start the engine to check if spark occurs at each cylinder. CHECK POWER SUPPLY CIRCUIT OF IGNITION COIL. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition coil. 3) Turn the ignition switch to ON. 4) Measure the voltage between ignition coil connector and engine ground. Connector & terminal (E31) No. 3 (+) Engine ground (): (E32) No. 3 (+) Engine ground (): (E33) No. 3 (+) Engine ground (): (E34) No. 3 (+) Engine ground (): (E45) No. 3 (+) Engine ground (): (E46) No. 3 (+) Engine ground (): CHECK HARNESS OF IGNITION COIL GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between ignition coil connector and engine ground. Connector & terminal (E31) No. 2 Engine ground: (E32) No. 2 Engine ground: (E33) No. 2 Engine ground: (E34) No. 2 Engine ground: (E45) No. 2 Engine ground: (E46) No. 2 Engine ground: Check Yes Is the spark plug condition nor- Go to step 2. mal? No Replace the spark plug. <Ref. to IG(H6DO)-4, Spark Plug.>
Does spark occur at each cylin- Check fuel pump Go to step 3. der? system. <Ref. to EN(H6DO)(diag)76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
Go to step 4.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit or short circuit to ground in power supply circuit Blown out of fuse Poor contact of coupling connector
CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 :? Go to step 6. NITION COIL CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and ignition coil connector. Connector & terminal (B137) No. 18 (E31) No. 1: (B137) No. 19 (E32) No. 1: (B137) No. 20 (E33) No. 1: (B137) No. 21 (E34) No. 1: (B137) No. 22 (E45) No. 1: (B137) No. 23 (E46) No. 1:
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM connector and the ignition coil connector Open circuit in harness between ECM and engine ground terminal Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and ignition coil connector Poor contact of coupling connector
EN(H6DO)(diag)-74

Step CHECK HARNESS BETWEEN ECM AND IGNITION COIL CONNECTOR. Measure the resistance of harness between ECM connector and chassis ground. Connector & terminal: (B137) No. 18 Chassis ground: (B137) No. 19 Chassis ground: (B137) No. 20 Chassis ground: (B137) No. 21 Chassis ground: (B137) No. 22 Chassis ground: (B137) No. 23 Chassis ground: CHECK POOR CONTACT. Check for poor contact of the ECM connector. Check Is the resistance 1 M: or more? Yes Go to step 7. No Repair the ground short circuit of harness between ECM and ignition coil connector.
Replace the ignition coil. <Ref. to IG(H6DO)-7, Ignition Coil.>
EN(H6DO)(diag)-75


BATTERY No.11 2 1 FUEL PUMP RELAY B362 7 20 B97 R1
10 FUEL PUMP CONTROL UNIT R122 7 6
9 8 R46 19 8 R67 ECM B33 C12
3 5
FUEL PUMP R58
5 6
5 R1 B97
B: B135 C: B136
B362
B97
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R67 1 2 3 4 5 6
R122
R58
B:
B135
C:
B136 5 6 14 15 16 25 26 27 33 34 35
1 2
3 4
3 4 1 2 5 6 7 8 9 10
5 7 8 6
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-05654
Step Check CHECK OPERATING SOUND OF FUEL Does the fuel pump emit operPUMP. ating sound? Make sure that the fuel pump operates for two seconds when turning the ignition switch to ON. NOTE: Fuel pump operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.>
Yes Check the fuel injector circuit. <Ref. to EN(H6DO)(diag)77, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
No Display the DTC. <Ref. to EN(H6DO)(diag)43, OPERATION, Read Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-76


CAUTION: Check or repair only faulty parts. After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY SBF-7 6 4 5 3 2 1 B47 B137 ECM BATTERY
10
12
11
13 47 E43 2 1 B21 E2 E44
42
48
43
44
E5 2 2 1 1
E16 2 1
E6 2 1
45
E17 2 1
46
E
FUEL INJECTOR No. 1 FUEL INJECTOR No. 2 FUEL INJECTOR No. 3 FUEL INJECTOR No. 4 FUEL INJECTOR No. 5 FUEL INJECTOR No. 6
E43 E5 E6 1 2
E44 E16 E17
B47 1 3 5 2 4 6
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06776
EN(H6DO)(diag)-77

Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit operTOR. ating sound? While cranking the engine, check each fuel injector emits operating sound. Use a sound scope or attach a screwdriver to the injector for this check. CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more? JECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel injector connector and the engine ground. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground (): #5 (E43) No. 2 (+) Engine ground (): #6 (E44) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and fuel injector connector. Connector & terminal #1 (B137) No. 8 (E5) No. 1: #2 (B137) No. 9 (E16) No. 1: #3 (B137) No. 10 (E6) No. 1: #4 (B137) No. 11 (E17) No. 1: #5 (B137) No. 12 (E43) No. 1: #6 (B137) No. 13 (E44) No. 1: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal #1 (B137) No. 8 Chassis ground: #2 (B137) No. 9 Chassis ground: #3 (B137) No. 10 Chassis ground: #4 (B137) No. 11 Chassis ground: #5 (B137) No. 12 Chassis ground: #6 (B137) No. 13 Chassis ground: CHECK EACH FUEL INJECTOR. Measure the resistance between each fuel injector terminals. Terminals No. 1 No. 2: CHECK POOR CONTACT. Check for poor contact of the ECM connector. Yes No Check the fuel Go to step 2. pressure. <Ref. to ME(H6DO)-27, INSPECTION, Fuel Pressure.> Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and fuel injector connector Poor contact of main relay connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector
Go to step 5.
Repair the short circuit to ground in harness between ECM and fuel injector connector.
Replace the faulty fuel injector. <Ref. to FU(H6DO)-28, Fuel Injector.> Inspection using General Diagnostic Table <Ref. to EN(H6DO)(diag)353, INSPECTION, General Diagnostic Table.>
EN(H6DO)(diag)-78


BATTERY No. 13
ECM A: B134 C: B136 D: B137
C16 C6
34 35 36 37 52 E2
* *
B122
D1 A3 D2 A5 D3 D7 B21
B40 1 2 3 4 5 6 7 8
B122 1 8 9 18 19 28 29
A: 2 10 20 30
B134
B21 9 10 11 12 13 14 15 16
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 B137
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2 3 4 5 6 7 8
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06866
EN(H6DO)(diag)-79

Step Check CHECK POWER SUPPLY CIRCUIT. Does SDI or general scan tool Connect the SDI (Subaru Diagnostic Interface) turn ON? to data link connector. CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 V or more? Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 16 (+) Chassis ground (): Yes Go to step 4. No Go to step 2.
Repair the power supply circuit. NOTE: In this case, repair the following item: Open or ground short circuit of harness between battery and data link connector Blown out of fuse (M/B No. 13) CHECK HARNESS BETWEEN DATA LINK Is the resistance less than 5 :? Repair the poor Repair the harness CONNECTOR AND CHASSIS GROUND. contact of data link and connector. 1) Turn the ignition switch to OFF. connector. NOTE: 2) Measure the resistance of harness between In this case, repair data link connector and chassis ground. the following item: Connector & terminal Open circuit of (B40) No. 4 Chassis ground: harness between (B40) No. 5 Chassis ground: ECM and data link connector Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 5. Repair the open DATA LINK CONNECTOR. circuit of harness 1) Disconnect the connector from ECM, TCM, between ECM and VDC CU, airbag CM and body integrated unit. data link connector. CAUTION: When disconnecting the connector from airbag control module, always follow the precautions on AB section. <Ref. to AB-4, CAUTION, General Description.> 2) Measure the resistance of harness between ECM and data link connector. Connector & terminal (B136) No. 16 (B40) No. 7: CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Repair the poor Repair the ground DATA LINK CONNECTOR. more? contact in the ECM short circuit of harMeasure the resistance between data link conor data link conness between nector and chassis ground. nector. ECM and data link Connector & terminal connector. (B40) No. 7 Chassis ground:
Go to step 3.
EN(H6DO)(diag)-80


A: LIST
DTC P0011 Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank1) Reference <Ref. to EN(H6DO)(diag)-89, DTC P0011 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-90, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft Position - Camshaft Posi- <Ref. to EN(H6DO)(diag)-91, DTC P0018 CRANKSHAFT POSITION - CAMtion Correlation (Bank2) SHAFT POSITION CORRELATION (BANK2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-92, DTC P0021 INTAKE CAMSHAFT POSITION Intake Camshaft Position - Timing TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Over-Advanced or System PerforDiagnostic Procedure with Diagnostic Trouble Code (DTC).> mance (Bank 2) Intake Valve Control Solenoid Circuit <Ref. to EN(H6DO)(diag)-93, DTC P0026 INTAKE VALVE CONTROL SOLERange/Performance (Bank 1) NOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Valve Control Solenoid Circuit <Ref. to EN(H6DO)(diag)-95, DTC P0028 INTAKE VALVE CONTROL SOLERange/Performance (Bank 2) NOID CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit (Bank 1 <Ref. to EN(H6DO)(diag)-97, DTC P0030 HO2S HEATER CONTROL CIRSensor 1) CUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit Low <Ref. to EN(H6DO)(diag)-99, DTC P0031 HO2S HEATER CONTROL CIR(Bank 1 Sensor 1) CUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit High <Ref. to EN(H6DO)(diag)-101, DTC P0032 HO2S HEATER CONTROL CIR(Bank 1 Sensor 1) CUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit Low <Ref. to EN(H6DO)(diag)-103, DTC P0037 HO2S HEATER CONTROL CIR(Bank 1 Sensor 2) CUIT LOW (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit High <Ref. to EN(H6DO)(diag)-105, DTC P0038 HO2S HEATER CONTROL CIR(Bank 1 Sensor 2) CUIT HIGH (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit (Bank 2 <Ref. to EN(H6DO)(diag)-107, DTC P0050 HO2S HEATER CONTROL CIRSensor 1) CUIT (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit Low <Ref. to EN(H6DO)(diag)-109, DTC P0051 HO2S HEATER CONTROL CIR(Bank 2 Sensor 1) CUIT LOW (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit High <Ref. to EN(H6DO)(diag)-111, DTC P0052 HO2S HEATER CONTROL CIR(Bank 2 Sensor 1) CUIT HIGH (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit Low <Ref. to EN(H6DO)(diag)-113, DTC P0057 HO2S HEATER CONTROL CIR(Bank 2 Sensor 2) CUIT LOW (BANK 2 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> HO2S Heater Control Circuit High <Ref. to EN(H6DO)(diag)-115, DTC P0058 HO2S HEATER CONTROL CIR(Bank 2 Sensor 2) CUIT HIGH (BANK 2 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> MAP/MAF - Throttle Position Correla- <Ref. to EN(H6DO)(diag)-117, DTC P0068 MAP/MAF - THROTTLE POSItion TION CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0016
P0018
P0021
P0026
P0028
P0030
P0031
P0032
P0037
P0038
P0050
P0051
P0052
P0057
P0058
P0068
EN(H6DO)(diag)-81

DTC P0076 Item Intake Valve Control Solenoid Circuit Low (Bank 1) Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Reference <Ref. to EN(H6DO)(diag)-119, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-121, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0077
P0082
P0083
P0101
P0102
P0103
P0107
P0108
P0111
P0112
P0113
P0117
P0118
P0122
P0123
P0125
P0126
<Ref. to EN(H6DO)(diag)-123, DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Valve Control Solenoid Circuit <Ref. to EN(H6DO)(diag)-125, DTC P0083 INTAKE VALVE CONTROL High (Bank 2) SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Mass or Volume Air Flow Circuit <Ref. to EN(H6DO)(diag)-127, DTC P0101 MASS OR VOLUME AIR FLOW Range/Performance CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Mass or Volume Air Flow Circuit Low <Ref. to EN(H6DO)(diag)-129, DTC P0102 MASS OR VOLUME AIR FLOW Input CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Mass or Volume Air Flow Circuit High <Ref. to EN(H6DO)(diag)-131, DTC P0103 MASS OR VOLUME AIR FLOW Input CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Manifold Absolute Pressure/Baro<Ref. to EN(H6DO)(diag)-133, DTC P0107 MANIFOLD ABSOLUTE PRESmetric Pressure Circuit Low Input SURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Manifold Absolute Pressure/Baro<Ref. to EN(H6DO)(diag)-135, DTC P0108 MANIFOLD ABSOLUTE PRESmetric Pressure Circuit High Input SURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Air Temperature Sensor 1 Cir- <Ref. to EN(H6DO)(diag)-137, DTC P0111 INTAKE AIR TEMPERATURE cuit Range/Performance SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Air Temperature Sensor 1 Cir- <Ref. to EN(H6DO)(diag)-139, DTC P0112 INTAKE AIR TEMPERATURE cuit Low SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake Air Temperature Sensor 1 Cir- <Ref. to EN(H6DO)(diag)-141, DTC P0113 INTAKE AIR TEMPERATURE cuit High SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Coolant Temperature Circuit <Ref. to EN(H6DO)(diag)-143, DTC P0117 ENGINE COOLANT TEMPERALow TURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Coolant Temperature Circuit <Ref. to EN(H6DO)(diag)-145, DTC P0118 ENGINE COOLANT TEMPERAHigh TURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H6DO)(diag)-147, DTC P0122 THROTTLE/PEDAL POSITION Switch A Circuit Low SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H6DO)(diag)-149, DTC P0123 THROTTLE/PEDAL POSITION Switch A Circuit High SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Insufficient Coolant Temperature for <Ref. to EN(H6DO)(diag)-151, DTC P0125 INSUFFICIENT COOLANT Closed Loop Fuel Control TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Insufficient Engine Coolant Tempera- <Ref. to EN(H6DO)(diag)-152, DTC P0126 INSUFFICIENT ENGINE COOLture For Stable Operation ANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-82

DTC P0128 Item Reference Coolant Thermostat (Engine Coolant <Ref. to EN(H6DO)(diag)-154, DTC P0128 COOLANT THERMOSTAT Temperature Below Thermostat Reg- (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATulating Temperature) ING TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Low Voltage (Bank <Ref. to EN(H6DO)(diag)-155, DTC P0131 O2 SENSOR CIRCUIT LOW 1 Sensor 1) VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit High Voltage <Ref. to EN(H6DO)(diag)-157, DTC P0132 O2 SENSOR CIRCUIT HIGH (Bank 1 Sensor 1) VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Slow Response <Ref. to EN(H6DO)(diag)-159, DTC P0133 O2 SENSOR CIRCUIT SLOW (Bank 1 Sensor 1) RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit No Activity <Ref. to EN(H6DO)(diag)-161, DTC P0134 O2 SENSOR CIRCUIT NO Detected (Bank 1 Sensor 1) ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Low Voltage (Bank <Ref. to EN(H6DO)(diag)-163, DTC P0137 O2 SENSOR CIRCUIT LOW 1 Sensor 2) VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit High Voltage <Ref. to EN(H6DO)(diag)-165, DTC P0138 O2 SENSOR CIRCUIT HIGH (Bank 1 Sensor 2) VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Slow Response <Ref. to EN(H6DO)(diag)-167, DTC P0139 O2 SENSOR CIRCUIT SLOW (Bank 1 Sensor 2) RESPONSE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit No Activity <Ref. to EN(H6DO)(diag)-169, DTC P0140 O2 SENSOR CIRCUIT NO Detected (Bank 1 Sensor 2) ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Low Voltage (Bank <Ref. to EN(H6DO)(diag)-172, DTC P0151 O2 SENSOR CIRCUIT LOW 2 Sensor 1) VOLTAGE (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit High Voltage <Ref. to EN(H6DO)(diag)-174, DTC P0152 O2 SENSOR CIRCUIT HIGH (Bank 2 Sensor 1) VOLTAGE (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Slow Response <Ref. to EN(H6DO)(diag)-176, DTC P0153 O2 SENSOR CIRCUIT SLOW (Bank 2 Sensor 1) RESPONSE (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit No Activity <Ref. to EN(H6DO)(diag)-178, DTC P0154 O2 SENSOR CIRCUIT NO Detected (Bank 2 Sensor 1) ACTIVITY DETECTED (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Low Voltage (Bank <Ref. to EN(H6DO)(diag)-180, DTC P0157 O2 SENSOR CIRCUIT LOW 2 Sensor 2) VOLTAGE (BANK 2 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit High Voltage <Ref. to EN(H6DO)(diag)-182, DTC P0158 O2 SENSOR CIRCUIT HIGH (Bank 2 Sensor 2) VOLTAGE (BANK 2 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit Slow Response <Ref. to EN(H6DO)(diag)-184, DTC P0159 O2 SENSOR CIRCUIT SLOW (Bank 2 Sensor 2) RESPONSE (BANK 2 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> O2 Sensor Circuit No Activity <Ref. to EN(H6DO)(diag)-186, DTC P0160 O2 SENSOR CIRCUIT NO Detected (Bank 2 Sensor 2) ACTIVITY DETECTED (BANK2 SENSOR2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> System Too Lean (Bank 1) <Ref. to EN(H6DO)(diag)-188, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> System Too Rich (Bank 1) <Ref. to EN(H6DO)(diag)-188, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0131
P0132
P0133
P0134
P0137
P0138
P0139
P0140
P0151
P0152
P0153
P0154
P0157
P0158
P0159
P0160
P0171 P0172
EN(H6DO)(diag)-83

DTC P0174 P0175 P0181 Reference <Ref. to EN(H6DO)(diag)-188, DTC P0174 SYSTEM TOO LEAN (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> System Too Rich (Bank 2) <Ref. to EN(H6DO)(diag)-189, DTC P0175 SYSTEM TOO RICH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Temperature Sensor A Circuit <Ref. to EN(H6DO)(diag)-191, DTC P0181 FUEL TEMPERATURE SENRange/Performance SOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Temperature Sensor A Circuit <Ref. to EN(H6DO)(diag)-193, DTC P0182 FUEL TEMPERATURE SENLow Input SOR A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Temperature Sensor A Circuit <Ref. to EN(H6DO)(diag)-195, DTC P0183 FUEL TEMPERATURE SENHigh Input SOR A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Oil Temperature Sensor Cir- <Ref. to EN(H6DO)(diag)-197, DTC P0196 ENGINE OIL TEMPERATURE cuit Range/Performance SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Oil Temperature Sensor Low <Ref. to EN(H6DO)(diag)-199, DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine Oil Temperature Sensor High <Ref. to EN(H6DO)(diag)-201, DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H6DO)(diag)-203, DTC P0222 THROTTLE/PEDAL POSITION Switch B Circuit Low SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle/Pedal Position Sensor/ <Ref. to EN(H6DO)(diag)-205, DTC P0223 THROTTLE/PEDAL POSITION Switch B Circuit High SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Pump Primary Circuit <Ref. to EN(H6DO)(diag)-207, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 1 Misfire Detected <Ref. to EN(H6DO)(diag)-209, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 2 Misfire Detected <Ref. to EN(H6DO)(diag)-209, DTC P0302 CYLINDER 2 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 3 Misfire Detected <Ref. to EN(H6DO)(diag)-209, DTC P0303 CYLINDER 3 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 4 Misfire Detected <Ref. to EN(H6DO)(diag)-209, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 5 Misfire Detected <Ref. to EN(H6DO)(diag)-209, DTC P0305 CYLINDER 5 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 6 Misfire Detected <Ref. to EN(H6DO)(diag)-210, DTC P0306 CYLINDER 6 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 1 Circuit Low (Bank 1 <Ref. to EN(H6DO)(diag)-216, DTC P0327 KNOCK SENSOR 1 CIRCUIT or Single Sensor) LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 1 Circuit High (Bank 1 <Ref. to EN(H6DO)(diag)-218, DTC P0328 KNOCK SENSOR 1 CIRCUIT or Single Sensor) HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 2 Circuit Low (Bank 2) <Ref. to EN(H6DO)(diag)-220, DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock Sensor 2 Circuit High (Bank 2) <Ref. to EN(H6DO)(diag)-222, DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft Position Sensor A Cir<Ref. to EN(H6DO)(diag)-224, DTC P0335 CRANKSHAFT POSITION SENcuit SOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Item System Too Lean (Bank 2)
P0182
P0183
P0196
P0197 P0198
P0222
P0223
P0230 P0301 P0302 P0303 P0304 P0305 P0306 P0327
P0328
P0332 P0333
P0335
EN(H6DO)(diag)-84

DTC P0336 Item Crankshaft Position Sensor A Circuit Range/Performance Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor) Camshaft Position Sensor A Circuit (Bank 2) Reference <Ref. to EN(H6DO)(diag)-226, DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-228, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0340
P0345
P0400 P0420
P0442
P0447
P0448
P0451
P0452
P0453
P0456
P0457
P0458
P0459
P0461
P0462 P0463 P0464
P0500
<Ref. to EN(H6DO)(diag)-230, DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Exhaust Gas Recirculation Flow <Ref. to EN(H6DO)(diag)-232, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Catalyst System Efficiency below <Ref. to EN(H6DO)(diag)-234, DTC P0420 CATALYST SYSTEM EFFIThreshold (Bank 1) CIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-238, DTC P0442 EVAPORATIVE EMISSION tem Leak Detected (Small Leak) CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-241, DTC P0447 EVAPORATIVE EMISSION tem Vent Control Circuit Open CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-243, DTC P0448 EVAPORATIVE EMISSION tem Vent Control Circuit Shorted CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-245, DTC P0451 EVAPORATIVE EMISSION tem Pressure Sensor CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-247, DTC P0452 EVAPORATIVE EMISSION tem Pressure Sensor Low Input CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-249, DTC P0453 EVAPORATIVE EMISSION tem Pressure Sensor High Input CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-251, DTC P0456 EVAPORATIVE EMISSION tem Leak Detected (Very Small CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Leak) Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission Control Sys<Ref. to EN(H6DO)(diag)-254, DTC P0457 EVAPORATIVE EMISSION tem Leak Detected (Fuel Cap Loose/ CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), DiagOff) nostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission System Purge <Ref. to EN(H6DO)(diag)-257, DTC P0458 EVAPORATIVE EMISSION SYSControl Valve Circuit Low TEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative Emission System Purge <Ref. to EN(H6DO)(diag)-259, DTC P0459 EVAPORATIVE EMISSION SYSControl Valve Circuit High TEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Level Sensor A Circuit Range/ <Ref. to EN(H6DO)(diag)-261, DTC P0461 FUEL LEVEL SENSOR A CIRPerformance CUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Level Sensor A Circuit Low <Ref. to EN(H6DO)(diag)-261, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Level Sensor A Circuit High <Ref. to EN(H6DO)(diag)-261, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel Level Sensor Circuit Intermittent <Ref. to EN(H6DO)(diag)-262, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Vehicle Speed Sensor A <Ref. to EN(H6DO)(diag)-262, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-85

DTC P0506 Item Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected Starter Request Circuit Incorrect Immobilizer Key Serial Communication Link Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (MIL Request) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (Low) (Bank 2 Sensor 1) O2 Sensor Circuit Range/Performance (High) (Bank 2 Sensor 1) Return Spring Failure Fuel Tank Pressure Control Solenoid Valve Circuit Low Fuel Tank Pressure Control Sol. Valve Circuit High Vent Control Solenoid Valve Function Problem EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) Reference <Ref. to EN(H6DO)(diag)-263, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-265, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-267, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-16, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-268, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-269, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-270, DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-271, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-272, DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-272, DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-273, DTC P1152 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-275, DTC P1153 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-277, DTC P1154 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (LOW) (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-279, DTC P1155 O2 SENSOR CIRCUIT RANGE/ PERFORMANCE (HIGH) (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-280, DTC P1160 RETURN SPRING FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-281, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-283, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-285, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-287, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-287, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0507
P0512 P0513 P0600 P0604
P0605
P0607
P0638
P0700
P1152
P1153
P1154
P1155
P1160 P1400
P1420
P1443
P1492
P1493
EN(H6DO)(diag)-86

DTC P1494 Item EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input) Back-Up Voltage Circuit Malfunction Reference <Ref. to EN(H6DO)(diag)-287, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-287, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-287, DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-287, DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-288, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-291, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-293, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-17, DTC P1570 ANTENNA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-19, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-20, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-23, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-23, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-24, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM(diag)-24, DTC P1578 METER FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-295, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-304, DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-306, DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-308, DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-310, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-311, DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1495
P1496
P1497
P1498
P1499
P1560
P1570 P1571 P1572
Antenna Reference Code Incompatibility IMM Circuit Failure (Except Antenna Circuit) Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Control Module Programming Error
P1574 P1576 P1577 P1578 P1602
P2088
Intake Camshaft Position Actuator Control Circuit Low (Bank 1) Intake Camshaft Position Actuator Control Circuit High (Bank 1) Intake Camshaft Position Actuator Control Circuit Low (Bank 2) Intake Camshaft Position Actuator Control Circuit High (Bank 2) Post Catalyst Fuel Trim System Too Lean (Bank 1)
P2089
P2092
P2093
P2096
EN(H6DO)(diag)-87

DTC P2097 Item Post Catalyst Fuel Trim System Too Rich (Bank 1) Post Catalyst Fuel Trim System Too Lean Bank 2 Post Catalyst Fuel Trim System Too Rich Bank 2 Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle/Pedal Position Sensor A Minimum Stop Performance Throttle/Pedal Position Sensor/ Switch D Circuit Low Input Throttle/Pedal Position Sensor/ Switch D Circuit High Input Throttle/Pedal Position Sensor/ Switch E Circuit Low Input Throttle/Pedal Position Sensor/ Switch E Circuit High Input Throttle/Pedal Position Sensor/ Switch A/B Voltage Correlation Throttle/Pedal Position Sensor/ Switch D/E Voltage Correlation Barometric Pressure Circuit Range/ Performance Barometric Pressure Circuit Low Barometric Pressure Circuit High Reference <Ref. to EN(H6DO)(diag)-312, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-317, DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-318, DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-324, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-329, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-331, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-332, DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-333, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-335, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-337, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-339, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-341, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-344, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-346, DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-346, DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(H6DO)(diag)-347, DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2098
P2099
P2101
P2102
P2103
P2109
P2122
P2123
P2127
P2128
P2135
P2138
P2227
P2228 P2229
EN(H6DO)(diag)-88


DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-10, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0? Yes Go to step 2. No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> <Ref. to LU(H6DO)-16, Engine Oil Filter.>
EN(H6DO)(diag)-89


DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0, and oil flow control solenoid valve duty output approx. 10%? Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> <Ref. to LU(H6DO)-16, Engine Oil Filter.> No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Timing chain (matching of timing mark)
EN(H6DO)(diag)-90


DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-13, DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0, and oil flow control solenoid valve duty output approx. 10%? Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> <Ref. to LU(H6DO)-16, Engine Oil Filter.> No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Timing chain (matching of timing mark)
EN(H6DO)(diag)-91

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-13, DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the AVCS system operating angle approx. 0? Yes Go to step 2. No Check the following item and repair or replace if necessary. Oil pipe (clog) Oil flow control solenoid valve (clogged or dirty oil passages, spring settings) Intake camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> <Ref. to LU(H6DO)-16, Engine Oil Filter.>
EN(H6DO)(diag)-92

E: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-14, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B20 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
B134 ECM
31
B134 1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B20 9 E1 VVL DIAGNOSIS OIL PRESSURE SWITCH RH 1 E71
EN-03913
EN(H6DO)(diag)-93

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and variable valve lift diagnosis oil pressure switch. 4) Measure the resistance of harness between ECM and variable valve lift diagnosis oil pressure switch connector. Connector & terminal (B134) No. 31 (E71) No. 1: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. Measure the resistance between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E71) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Turn the ignition switch to ON. 2) Measure the voltage between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E71) No. 1 (+) Engine ground (): CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> Is the resistance 1 M: or more? Go to step 3. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and variable valve lift diagnosis oil pressure switch connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and variable valve lift diagnosis oil pressure switch connector.
Repair the short Go to step 4. circuit of harness to power supply between ECM and variable valve lift diagnosis oil pressure switch connector. Replace the oil End. switching solenoid valve. <Ref. to ME(H6DO)-80, Oil Switching Solenoid Valve.> Go to step 5. Check for oil routing. End.
Is DTC displayed?
Is DTC displayed?
EN(H6DO)(diag)-94

F: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-16, DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B20 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
B134 ECM
32
B134 1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B20 10 E1 VVL DIAGNOSIS OIL PRESSURE SWITCH LH 1 E72
EN-03914
EN(H6DO)(diag)-95

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and variable valve lift diagnosis oil pressure switch. 4) Measure the resistance of harness between ECM and variable valve lift diagnosis oil pressure switch connector. Connector & terminal (B134) No. 32 (E72) No. 1: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. Measure the resistance between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E72) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH. 1) Turn the ignition switch to ON. 2) Measure the voltage between variable valve lift diagnosis oil pressure switch connector and engine ground. Connector & terminal (E72) No. 1 (+) Engine ground (): CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedure, refer to Clear Memory Mode. <Ref. to EN(H6DO)(diag)-52, Clear Memory Mode.> Is the resistance 1 M: or more? Go to step 3. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and variable valve lift diagnosis oil pressure switch connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and variable valve lift diagnosis oil pressure switch connector.
Repair the short Go to step 4. circuit of harness to power supply between ECM and variable valve lift diagnosis oil pressure switch connector. Replace the oil End. switching solenoid valve. <Ref. to ME(H6DO)-80, Oil Switching Solenoid Valve.> Go to step 5. Check for oil routing. End.
Is DTC displayed?
Is DTC displayed?
EN(H6DO)(diag)-96

G: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-17, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY SBF-5 6 4 5 3 2 1 B47 B22 2 2 BATTERY
8 E3
FRONT OXYGEN (A/F) SENSOR LH E24
FRONT OXYGEN (A/F) SENSOR RH E47
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-97

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 2 (E47) No. 1: (B136) No. 3 (E47) No. 1: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 9 (E47) No. 3: (B135) No. 8 (E47) No. 4: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 4. Replace the front oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.> Repair the poor Replace the front contact in ECM or oxygen (A/F) senfront oxygen (A/F) sor. <Ref. to sensor connector. FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
EN(H6DO)(diag)-98


DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-19, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-99

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E47) No. 2 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. NOTE: In this case, repair the following item: Open circuit of harness between main relay and front oxygen (A/F) sensor connector Poor contact of main relay connector Poor contact of coupling connector Malfunction of main relay Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the front oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 No. 1:
EN(H6DO)(diag)-100

I:
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-21, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-101

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 2 (+) Chassis ground (): (B136) No. 3 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and front oxygen (A/F) sensor connector.
EN(H6DO)(diag)-102

J: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-23, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY SBF-5 6 4 5 3 2 1 B47 13 15 16 12 10 11 9 B22 2 2 BATTERY
14 E3
E25
REAR OXYGEN SENSOR RH
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-103

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (E61) No. 2 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. NOTE: In this case, repair the following item: Open circuit of harness between main relay and rear oxygen sensor Poor contact of main relay connector Poor contact of coupling connector Malfunction of main relay Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the rear oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.>
CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor connector terminals. Terminals No. 2 No. 1:
EN(H6DO)(diag)-104

K: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-25, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-105

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 4 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and rear oxygen sensor connector. Repair the poor contact of ECM connector. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector
EN(H6DO)(diag)-106

L: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-26, DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-107

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 6 (E24) No. 1: (B135) No. 7 (E24) No. 1: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 11 (E24) No. 3: (B135) No. 10 (E24) No. 4: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Go to step 4. Replace the front oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.> Repair the poor Replace the front contact in ECM or oxygen (A/F) senfront oxygen (A/F) sor. <Ref. to sensor connector. FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
Is the resistance less than 2 3 :?
EN(H6DO)(diag)-108

M: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-26, DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-109

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E24) No. 2 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. NOTE: In this case, repair the following item: Open circuit of harness between main relay and front oxygen (A/F) sensor connector Poor contact of main relay connector Poor contact of coupling connector Malfunction of main relay Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the front oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 No. 1:
EN(H6DO)(diag)-110

N: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-26, DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-111

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 6 (+) Chassis ground (): (B135) No. 7 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and front oxygen (A/F) sensor connector.
EN(H6DO)(diag)-112

O: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-26, DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-113

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (E25) No. 2 (+) Engine ground (): Yes Go to step 2. No Repair the power supply line. NOTE: In this case, repair the following item: Open circuit of harness between main relay and rear oxygen sensor Poor contact of main relay connector Poor contact of coupling connector Malfunction of main relay Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the rear oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.>
CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor connector terminals. Terminals No. 2 No. 1:
EN(H6DO)(diag)-114

P: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-26, DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-115

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 5 (+) Chassis ground (): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 :? 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and rear oxygen sensor connector. Repair the poor contact of ECM connector. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector
EN(H6DO)(diag)-116

Q: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-27, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E21
1 2 3
1 2 3
E21 E77 1 2 3 4 5 6 7 10 8 9
E77 5 8 1 E76 B134 1 8 9 18 19 28 29 E2 19 7 20 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134
29 6 19 ECM
EN-06869
EN(H6DO)(diag)-117

Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK MANIFOLD ABSOLUTE PRESSURE Is the measured value 73.3 Go to step 3. SENSOR. 106.6 kPa (550 800 mmHg, 1) Start the engine and warm up engine until 21.65 31.50 inHg) when the coolant temperature is higher than 75C ignition is turned ON, and 20.0 (167F). 46.7 kPa (150 350 mmHg, 2) Place the select lever in P range or N 5.91 13.78 inHg) during range. idling? 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the General Scan Tool Instruction Manual. CHECK THROTTLE OPENING ANGLE. Is the measured value less than Go to step 4. Read the data of throttle position signal using 5% when throttle is fully Subaru Select Monitor or general scan tool. closed? NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the General Scan Tool Instruction Manual. CHECK THROTTLE OPENING ANGLE. Is the measured value 85% or Replace the manimore when throttle is fully fold absolute presopen? sure sensor. <Ref. to FU(H6DO)-25, Manifold Absolute Pressure Sensor.> Step CHECK AIR INTAKE SYSTEM. No Go to step 2.
Replace the manifold absolute pressure sensor. <Ref. to FU(H6DO)-25, Manifold Absolute Pressure Sensor.>
Replace the electronic throttle control. <Ref. to FU(H6DO)-13, Throttle Body.>
EN(H6DO)(diag)-118

R: DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-29, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM
25
24
E69 1 2
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21
B21 E2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
25 26 1 2
E69
EN-06870
EN(H6DO)(diag)-119

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the resistance of harness between ECM and oil switching solenoid valve. Connector & terminal (B137) No. 25 (E69) No. 1: (B137) No. 24 (E69) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and oil switching solenoid valve connector. Replace the oil switching solenoid valve. <Ref. to ME(H6DO)-80, Oil Switching Solenoid Valve.>
Go to step 3.
EN(H6DO)(diag)-120

S: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-30, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM
25
24
E69 1 2
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21
B21 E2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
25 26 1 2
E69
EN-06870
EN(H6DO)(diag)-121

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 25 (+) Chassis ground (): (B137) No. 24 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 3. SWITCHING SOLENOID VALVE. Measure the resistance of harness between ECM and oil switching solenoid valve connector. Connector & terminal (B137) No. 25 (E69) No. 1: (B137) No. 24 (E69) No. 2: No Repair the short circuit of harness to power supply between ECM and oil switching solenoid valve connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Replace the oil CHECK OIL SWITCHING SOLENOID VALVE. Is the resistance between 6 Repair the poor switching solenoid contact of ECM Measure the resistance between oil switching 12 :? valve. <Ref. to and oil switching solenoid valve terminals. solenoid valve con- ME(H6DO)-80, Oil Terminals Switching Solenoid nector. No. 1 No. 2: Valve.>
EN(H6DO)(diag)-122

T: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-30, DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM
31
30
E70 1 2
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21
B21 E2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
29 30 1 2
E70
EN-06871
EN(H6DO)(diag)-123

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the resistance between ECM and oil switching solenoid valve. Connector & terminal (B137) No. 31 (E70) No. 1: (B137) No. 30 (E70) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and oil switching solenoid valve connector. Replace the oil switching solenoid valve. <Ref. to ME(H6DO)-80, Oil Switching Solenoid Valve.>
Go to step 3.
EN(H6DO)(diag)-124

U: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-30, DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM
31
30
E70 1 2
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21
B21 E2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
29 30 1 2
E70
EN-06871
EN(H6DO)(diag)-125

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. SWITCHING SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 31 (+) Chassis ground (): (B137) No. 30 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 3. SWITCHING SOLENOID VALVE. Measure the resistance between ECM and oil switching solenoid valve connector. Connector & terminal (B137) No. 31 (E70) No. 1: (B137) No. 30 (E70) No. 2: No Repair the short circuit of harness to power supply between ECM and oil switching solenoid valve connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and oil switching solenoid valve connector Poor contact of coupling connector Replace the oil CHECK OIL SWITCHING SOLENOID VALVE. Is the resistance between 6 Repair the poor switching solenoid contact of ECM Measure the resistance between oil switching 12 :? valve. <Ref. to and oil switching solenoid valve terminals. solenoid valve con- ME(H6DO)-80, Oil Terminals Switching Solenoid nector. No. 1 No. 2: Valve.>
EN(H6DO)(diag)-126

V: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-31, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
* *
B83
26
30
35
18
34
E
B135 ECM
B3
B47 1 3 5 2 4 6
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 2 3 4 5 6 7 8
EN-03920
EN(H6DO)(diag)-127

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> No Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.>
EN(H6DO)(diag)-128

W: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-33, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
* *
B83
26
30
35
18
34
E
B135 ECM
B3
B47 1 3 5 2 4 6
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 2 3 4 5 6 7 8
EN-03920
EN(H6DO)(diag)-129

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF MASS AIR Is the voltage 10 V or more? FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the mass air flow and intake air temperature sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 1 (+) Engine ground (): Go to step 3. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and mass air flow and intake air temperature sensor connector Poor contact of main relay connector Repair the open circuit of harness between ECM and mass air flow and intake air temperature sensor connector.
Repair the ground short circuit of harness between the ECM and the mass air flow and intake air temperature sensor connectors. Repair any poor Replace the mass contact in the ECM air flow and intake or the mass air flow air temperature and intake air tem- sensor. <Ref. to perature sensor FU(H6DO)-26, Mass Air Flow and connector. Intake Air Temperature Sensor.>
Go to step 5.
EN(H6DO)(diag)-130

X: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-34, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
* *
B83
26
30
35
18
34
E
B135 ECM
B3
B47 1 3 5 2 4 6
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 2 3 4 5 6 7 8
EN-03920
EN(H6DO)(diag)-131

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the mass air flow and intake air temperature sensor. 3) Start the engine. 4) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 :? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 2 Engine ground: Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and mass air flow and intake air temperature sensor connectors. Poor contact in ECM connector CHECK POOR CONTACT. Is there poor contact in the Repair any poor Replace the mass Check for any poor contact in the mass air flow mass air flow and intake air contact of the air flow and intake and intake air temperature sensor connector. temperature sensor connector? mass air flow and air temperature intake air temperasensor. <Ref. to ture sensor conFU(H6DO)-26, nector. Mass Air Flow and Intake Air Temperature Sensor.>
Go to step 4.
EN(H6DO)(diag)-132

Y: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-35, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E21
1 2 3
1 2 3
E21 E77 1 2 3 4 5 6 7 10 8 9
E77 5 8 1 E76 B134 1 8 9 18 19 28 29 E2 19 7 20 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134
29 6 19 ECM
EN-06869
EN(H6DO)(diag)-133

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Start the engine. 13.3 kPa (100 mmHg, 3.94 inHg)? 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POWER SUPPLY OF MANIFOLD Is the voltage 4.5 V or more? Go to step 3. ABSOLUTE PRESSURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) Engine ground (): No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact in ECM connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact of coupling connector Repair ground short circuit of harness between ECM and manifold absolute pressure sensor connector. Replace the manifold absolute pressure sensor. <Ref. to FU(H6DO)-25, Manifold Absolute Pressure Sensor.>
Go to step 5.
EN(H6DO)(diag)-134

Z: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-36, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/ BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E21
1 2 3
1 2 3
E21 E77 1 2 3 4 5 6 7 10 8 9
E77 5 8 1 E76 B134 1 8 9 18 19 28 29 E2 19 7 20 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134
29 6 19 ECM
EN-06869
EN(H6DO)(diag)-135

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Start the engine. 4) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 1 Engine ground: Check Yes Is the measured value 119.5 kPa Go to step 2. (896.5 mmHg, 35.29 inHg) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and manifold absolute pressure sensor connector. Poor contact in ECM connector Poor contact of coupling connector Replace the maniRepair the poor fold absolute prescontact of manifold absolute pressure sensor. <Ref. to FU(H6DO)-25, sure sensor connector. Manifold Absolute Pressure Sensor.>
EN(H6DO)(diag)-136

AA:DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-37, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
* *
B83
26
30
35
18
34
E
B135 ECM
B3
B47 1 3 5 2 4 6
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 2 3 4 5 6 7 8
EN-03920
EN(H6DO)(diag)-137

Step Check CHECK ENGINE COOLANT TEMPERAIs the engine coolant temperaTURE. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Measure the engine coolant temperature using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Yes Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.> No Check DTC P0125 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-138

AB:DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-39, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
* *
B83
26
30
35
18
34
E
B135 ECM
B3
B47 1 3 5 2 4 6
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 2 3 4 5 6 7 8
EN-03920
EN(H6DO)(diag)-139

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and mass air flow and intake air temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 18 Chassis ground: Check Is the intake air temperature 120C (248F) or higher? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the ground short circuit of harness between the ECM and the mass air flow and intake air temperature sensor connectors.
Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.>
EN(H6DO)(diag)-140

AC:DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-40, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
* *
B83
26
30
35
18
34
E
B135 ECM
B3
B47 1 3 5 2 4 6
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B83
1 2 3 4 5
1 2 3 4 5 6 7 8
EN-03920
EN(H6DO)(diag)-141

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact in the ECM or the mass air flow and intake air temperature sensor connector. Check Is the intake air temperature less than 40C (40F) ? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Repair any poor contact in the ECM or the mass air flow and intake air temperature sensor connector. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the open MASS AIR FLOW AND INTAKE AIR TEMcircuit of harness PERATURE SENSOR CONNECTOR. between ECM and 1) Turn the ignition switch to OFF. mass air flow and 2) Disconnect the connector from ECM and intake air temperamass air flow and intake air temperature sensor. ture sensor con3) Measure the resistance of harness between nector. ECM and mass air flow and intake air temperature sensor connectors. Connector & terminal (B135) No. 18 (B3) No. 4: (B135) No. 30 (B3) No. 5: CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? Repair the short Replace the mass MASS AIR FLOW AND INTAKE AIR TEMcircuit to power in air flow and intake PERATURE SENSOR CONNECTOR. the harness air temperature 1) Connect all connectors. between the ECM sensor. <Ref. to 2) Turn the ignition switch to ON. and the mass air FU(H6DO)-26, 3) Disconnect the connector from the mass air flow and intake air Mass Air Flow and flow and intake air temperature sensor. temperature sen- Intake Air Temper4) Measure the voltage between ECM and sor connector. ature Sensor.> chassis ground. Connector & terminal (B135) No. 18 (+) Chassis ground ():
EN(H6DO)(diag)-142

AD:DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-41, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 1
E8 E8 1 2
B134 1 8 9 18 19 28 29 E2 8 19 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134
34 29 ECM
EN-06872
EN(H6DO)(diag)-143

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 34 Chassis ground: Check Yes Is the engine coolant tempera- Go to step 2. ture 150C (302F) or higher? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the short circuit to ground in harness between ECM and engine coolant temperature sensor.
Replace the engine coolant temperature sensor. <Ref. to FU(H6DO)-20, Engine Coolant Temperature Sensor.>
EN(H6DO)(diag)-144

AE:DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-42, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 1
E8 E8 1 2
B134 1 8 9 18 19 28 29 E2 8 19 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134
34 29 ECM
EN-06872
EN(H6DO)(diag)-145

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact in ECM and engine coolant temperature sensor connector. Check Yes Is the engine coolant tempera- Go to step 2. ture less than 40C (40F) ? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is there poor contact in ECM or Repair the poor engine coolant temperature contact in ECM or engine coolant sensor connector? temperature sensor connector. CHECK HARNESS BETWEEN ECM AND EN- Is the resistance less than 1 :? Go to step 4. Repair the harness GINE COOLANT TEMPERATURE SENSOR and connector. CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM and the following item: engine coolant temperature sensor. Open circuit in 3) Measure the resistance of harness between harness between ECM and engine coolant temperature sensor ECM and engine connector. coolant temperaConnector & terminal ture sensor con(B134) No. 34 (E8) No. 2: nector (B134) No. 29 (E8) No. 1: Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND EN- Is the voltage 5 V or more? Repair the short Replace the GINE COOLANT TEMPERATURE SENSOR circuit to power in engine coolant CONNECTOR. harness between temperature sen1) Connect all connectors. ECM and engine sor. <Ref. to 2) Turn the ignition switch to ON. coolant tempera- FU(H6DO)-20, 3) Measure the voltage between ECM and ture sensor conEngine Coolant chassis ground. nector. Temperature SenConnector & terminal sor.> (B134) No. 34 (+) Chassis ground ():
EN(H6DO)(diag)-146

AF:DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-43, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-06873
EN(H6DO)(diag)-147

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
EN(H6DO)(diag)-148

AG:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-44, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-06873
EN(H6DO)(diag)-149

Repair the short circuit to power in the harness between ECM and electronic throttle control connector. Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H6DO)-13, Throttle Body.>
EN(H6DO)(diag)-150

AH:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-45, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine does not return to idle. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
Replace the thermostat. <Ref. to CO(H6DO)-13, Thermostat.>
Fill or replace the engine coolant. <Ref. to CO(H6DO)-10, Engine Coolant.> Replace the engine coolant temperature sensor. <Ref. to FU(H6DO)-20, Engine Coolant Temperature Sensor.>
EN(H6DO)(diag)-151

AI: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-47, DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 1
E8 E8 1 2
B134 1 8 9 18 19 28 29 E2 8 19 B21 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B134
34 29 ECM
EN-06872
EN(H6DO)(diag)-152

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure the resistance between engine coolant temperature sensor terminals when the engine coolant is cold and after warmed up. Terminals No. 1 No. 2: Check Yes Is the resistance of engine cool- Repair the poor ant temperature sensor differ- contact of ECM ent between when engine connector. coolant is cold and after warmed up? No Replace the engine coolant temperature sensor. <Ref. to FU(H6DO)-20, Engine Coolant Temperature Sensor.>
EN(H6DO)(diag)-153

AJ:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-49, DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Thermostat remains open. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step CHECK ENGINE COOLANT. Check Are the coolant level and mixture ratio of engine coolant to anti-freeze solution correct? Yes Go to step 2. No Replace the engine coolant. <Ref. to CO(H6DO)-10, REPLACEMENT, Engine Coolant.> Repair radiator fan Replace the thercircuit. <Ref. to mostat. <Ref. to CO(H6DO)-19, CO(H6DO)-13, Radiator Main Fan Thermostat.> and Fan Motor.> and <Ref. to CO(H6DO)-22, Radiator Sub Fan and Fan Motor.>
EN(H6DO)(diag)-154

AK:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-51, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-155

Replace the front oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
EN(H6DO)(diag)-156

AL:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-53, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-157

EN(H6DO)(diag)-158

AM:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-55, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-159

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a hole Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
EN(H6DO)(diag)-160

AN:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-58, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-161

No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor. <Ref. to sensor connector. FU(H6DO)-32, Front Oxygen (A/F) Sensor.> Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 9 (E47) No. 3: (B135) No. 8 (E47) No. 4:
EN(H6DO)(diag)-162

AO:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-60, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-163

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E61) No. 3: (B135) No. 30 (E61) No. 4: No Go to step 2.
Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H6DO)-34, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Repair or replace Replace the rear faulty parts. oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.>
EN(H6DO)(diag)-164

AP:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-63, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-165

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E61) No. 3: (B135) No. 30 (E61) No. 4: No Go to step 2.
Go to step 3.
EN(H6DO)(diag)-166

AQ:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-167

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E61) No. 3: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Is the resistance 1 M: or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 :? Replace the rear Even if DTC is oxygen sensor. detected, the cir<Ref. to cuit has returned to FU(H6DO)-34, a normal condition Rear Oxygen Sen- at this time. Reprosor.> duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 Chassis ground CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 No. 4
EN(H6DO)(diag)-168

AR:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-69, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30
EN-06868
EN(H6DO)(diag)-169

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E61) No. 3: (B135) No. 30 (E61) No. 4: Check Yes Is the voltage 490 mV or more? Go to step 6. No Go to step 2.
Go to step 3.
Go to step 4.
EN(H6DO)(diag)-170

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 0.5 V? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) Chassis ground (): Yes Replace the rear oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.> No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Replace the rear oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.>
EN(H6DO)(diag)-171

AS:DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-71, DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-172

EN(H6DO)(diag)-173

AT:DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-71, DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-174

EN(H6DO)(diag)-175

AU:DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1)

8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-176

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a hole Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
EN(H6DO)(diag)-177

AV:DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-71, DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-178

No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor. <Ref. to sensor connector. FU(H6DO)-32, Front Oxygen (A/F) Sensor.> Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 11 (E24) No. 3: (B135) No. 10 (E24) No. 4:
EN(H6DO)(diag)-179

AW:DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-71, DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-180

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 15 (E25) No. 3: (B135) No. 30 (E25) No. 4: No Go to step 2.
Go to step 3.
EN(H6DO)(diag)-181

AX:DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-71, DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-182

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 15 (E25) No. 3: (B135) No. 30 (E25) No. 4: No Go to step 2.
Go to step 3.
EN(H6DO)(diag)-183

AY:DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2)

14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-184

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 15 (E25) No. 3: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Is the resistance 1 M: or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 :? Replace the rear Even if DTC is oxygen sensor. detected, the cir<Ref. to cuit has returned to FU(H6DO)-34, a normal condition Rear Oxygen Sen- at this time. Reprosor.> duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (B25) No. 3 Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 No. 4
EN(H6DO)(diag)-185

AZ:DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-71, DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30
EN-06868
EN(H6DO)(diag)-186

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 15 (E25) No. 3: (B135) No. 30 (E25) No. 4: Check Yes Is the voltage 490 mV or more? Go to step 6. No Go to step 2.
Go to step 3.
Go to step 4.
EN(H6DO)(diag)-187

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 0.2 0.5 V? REAR OXYGEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) Chassis ground (): Yes Replace the rear oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.> No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and rear oxygen sensor Poor contact of the rear oxygen sensor connector Poor contact in ECM connector Replace the rear oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.>
BA:DTC P0171 SYSTEM TOO LEAN (BANK 1)

NOTE: Refer to DTC P0175 for diagnostic procedure. <Ref. to EN(H6DO)(diag)-189, DTC P0175 SYSTEM TOO RICH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB:DTC P0172 SYSTEM TOO RICH (BANK 1)

BC:DTC P0174 SYSTEM TOO LEAN (BANK 2)

EN(H6DO)(diag)-188

BD:DTC P0175 SYSTEM TOO RICH (BANK 2)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-74, DTC P0175 SYSTEM TOO RICH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 2 Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 333 343 kPa (3.4 3.5 kgf/cm2, WARNING: Place NO OPEN FLAMES signs near the 48.4 49.8 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. <Ref. to ME(H6DO)-27, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant temperaSENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Step CHECK EXHAUST SYSTEM. Yes No Repair the exhaust Go to step 2. system. Repair the air Go to step 3. intake system. Go to step 4. Repair the following item. Fuel pressure is too high: Clogged fuel line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel line Replace the engine coolant temperature sensor. <Ref. to FU(H6DO)-20, Engine Coolant Temperature Sensor.>
Go to step 5.
EN(H6DO)(diag)-189

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR SIGNAL. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Check Is the measured value 2.0 5.0 g/s (0.26 0.66 lb/m)? Yes Go to step 6. No Replace the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.>
Check the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.>
EN(H6DO)(diag)-190

BE:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-75, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
FUEL PUMP ASSY FUEL TEMPERATURE SENSOR
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
17 30
B135 ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35
B83
1 2 3 4 5 6 7 8
EN-05659
EN(H6DO)(diag)-191

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> No Replace the fuel temperature sensor. <Ref. to EC(H6DO)-10, Fuel Temperature Sensor.>
EN(H6DO)(diag)-192

BF:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-78, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
17 30
B135 ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35
B83
1 2 3 4 5 6 7 8
EN-05659
EN(H6DO)(diag)-193

Step Check CHECK CURRENT DATA. Is the temperature 120C 1) Start the engine. (248F) or higher? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the ground short circuit of harness between ECM and fuel pump.
Replace the fuel temperature sensor. <Ref. to EC(H6DO)-10, Fuel Temperature Sensor.>
EN(H6DO)(diag)-194

BG:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-79, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
2 3 R58 R67 1 4 R46 R1 4 18 B97
* *
B83
17 30
B135 ECM
R67 1 2 3 4 5 6
R58 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35
B83
1 2 3 4 5 6 7 8
EN-05659
EN(H6DO)(diag)-195

Step Check CHECK CURRENT DATA. Is the temperature less than 1) Start the engine. 40C (40F)? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance of the harness between the ECM and fuel temperature sensor connector. Connector & terminal (B135) No. 17 (R58) No. 2: (B135) No. 30 (R58) No. 3: CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 17 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and fuel temperature sensor connector Poor contact of coupling connector Repair the short Replace the fuel circuit to power in temperature senthe harness sor. <Ref. to between the ECM EC(H6DO)-10, and fuel tempera- Fuel Temperature ture sensor conSensor.> nector.
EN(H6DO)(diag)-196

BH:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-80, DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E75 1 2
E75
B20 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
E1 19 3 B20
E2 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
23 29
B134 ECM
EN-06874
EN(H6DO)(diag)-197

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> No Replace the oil temperature sensor. <Ref. to FU(H6DO)-31, Oil Temperature Sensor.>
EN(H6DO)(diag)-198

BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-82, DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E75 1 2
E75
B20 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
E1 19 3 B20
E2 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
23 29
B134 ECM
EN-06874
EN(H6DO)(diag)-199

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND OIL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and oil temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 23 Chassis ground: Check Is the oil temperature 215C (419F) or more? Yes Go to step 2. No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Replace the oil Repair the short temperature sen- circuit to ground in harness between sor. <Ref. to FU(H6DO)-31, Oil ECM and oil temTemperature Sen- perature sensor. sor.>
EN(H6DO)(diag)-200

BJ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-83, DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E75 1 2
E75
B20 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
E1 19 3 B20
E2 B21 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
23 29
B134 ECM
EN-06874
EN(H6DO)(diag)-201

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK POOR CONTACT. Check for poor contact of ECM and oil temperature sensor connector. Check Yes Is the oil temperature less than Go to step 2. 40C (40F)? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is there poor contact in ECM or Repair the poor oil temperature sensor connec- contact in ECM or oil temperature tor? sensor connector. CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 4. Repair the harness TEMPERATURE SENSOR CONNECTOR. and connector. 1) Turn the ignition switch to OFF. NOTE: 2) Disconnect the connector from ECM and oil In this case, repair temperature sensor. the following item: 3) Measure the resistance of harness between Open circuit in ECM and oil temperature sensor connector. harness between Connector & terminal ECM and oil tem(B134) No. 23 (E75) No. 2: perature sensor (B134) No. 29 (E75) No. 1: connector Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND OIL Is the voltage 5 V or more? Repair the short Replace the oil TEMPERATURE SENSOR CONNECTOR. circuit in harness temperature sen1) Connect all connectors. to power supply sor. <Ref. to 2) Turn the ignition switch to ON. between ECM and FU(H6DO)-31, Oil 3) Measure the voltage between ECM and oil temperature Temperature Senchassis ground. sensor connector. sor.> Connector & terminal (B134) No. 23 (+) Chassis ground ():
EN(H6DO)(diag)-202

BK:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-84, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-06873
EN(H6DO)(diag)-203

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
EN(H6DO)(diag)-204

BL:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-85, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-06873
EN(H6DO)(diag)-205

Repair the short circuit to power in the harness between ECM and electronic throttle control connector. Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H6DO)-13, Throttle Body.>
EN(H6DO)(diag)-206

BM:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-86, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY No.11 2 1 FUEL PUMP RELAY B362 7 20 B97 R1
10 FUEL PUMP CONTROL UNIT R122 7 6
9 8 R46 19 8 R67 ECM B33 C12
3 5
FUEL PUMP R58
5 6
5 R1 B97
B: B135 C: B136
B362
B97
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R67 1 2 3 4 5 6
R122
R58
B:
B135
C:
B136 5 6 14 15 16 25 26 27 33 34 35
1 2
3 4
3 4 1 2 5 6 7 8 9 10
5 7 8 6
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-05654
EN(H6DO)(diag)-207

Step Check CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage 10 V or more? PUMP CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel pump control unit. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 10 (+) Chassis ground (): Yes Go to step 2. No Repair the power supply circuit. NOTE: In this case, repair the following item: Open or ground short circuit of harness between fuel pump relay and fuel pump control unit connector Poor contact of fuel pump control unit connector Poor contact of fuel pump relay connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit between fuel pump control unit connector and chassis ground Poor contact of fuel pump control unit connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in haness between fuel pump control unit connector and fuel pump connector Poor contact of coupling connector Repair the short circuit to ground in harness between fuel pump control unit connector and fuel pump connector.
CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5 :? Go to step 3. CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 5 Chassis ground:
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 :? Go to step 4. CONTROL UNIT AND FUEL PUMP CONNECTOR. 1) Disconnect the connector from fuel pump. 2) Measure the resistance of harness between fuel pump control unit and fuel pump connector. Connector & terminal (R122) No. 7 (R58) No. 5: (R122) No. 6 (R58) No. 6:
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance 1 M: or CONTROL UNIT AND FUEL PUMP CONNEC- more? TOR. Measure the resistance between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 7 Chassis ground: (R122) No. 6 Chassis ground:
Go to step 5.
EN(H6DO)(diag)-208

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 6. FUEL PUMP CONTROL UNIT. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and fuel pump control unit. Connector & terminal (B136) No. 12 (R122) No. 8: (B135) No. 33 (R122) No. 9: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and fuel pump control unit connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and fuel pump control unit connector. Go to step 8.
CHECK HARNESS BETWEEN ECM AND FUEL PUMP CONTROL UNIT. Measure the resistance between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 8 Chassis ground: (R122) No. 9 Chassis ground: CHECK POOR CONTACT. Check for poor contact of ECM and fuel pump control unit connector.
Go to step 7.
Is there poor contact in ECM or Repair the poor fuel pump control unit connec- contact of ECM or fuel pump control tor? unit connector. CHECK EXPERIENCE OF RUNNING OUT OF Has the vehicle experienced Finish the diagnoFUEL. running out of fuel? sis. NOTE: DTC may be recorded as a result of fuel pump idling while running out of fuel.
Replace the fuel pump control unit. <Ref. to FU(H6DO)-42, Fuel Pump Control Unit.>
BN:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE: For the diagnostic procedure, refer to DTC P0306. <Ref. to EN(H6DO)(diag)-210, DTC P0306 CYLINDER 6 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BO:DTC P0302 CYLINDER 2 MISFIRE DETECTED

BP:DTC P0303 CYLINDER 3 MISFIRE DETECTED

BQ:DTC P0304 CYLINDER 4 MISFIRE DETECTED

BR:DTC P0305 CYLINDER 5 MISFIRE DETECTED

EN(H6DO)(diag)-209

BS:DTC P0306 CYLINDER 6 MISFIRE DETECTED

DTC DETECTING CONDITION: Two consecutive driving cycles with fault Immediately at fault recognition (A misfire which could damage catalyst occurs.) GENERAL DESCRIPTION <Ref. to GD(H6DO)-93, DTC P0306 CYLINDER 6 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Improper idling Rough driving CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
10
12
11
13 47 E43 2 1 B21 E2 E44
48
42
43
44
E5 2 1 2 1
E16 2 1
E6 2 1
45
E17 2 1
46
E
E43 E5 E6 1 2
E44 E16 E17
B47 1 3 5 2 4 6
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06776
EN(H6DO)(diag)-210

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): #5 (B137) No. 12 (+) Chassis ground (): #6 (B137) No. 13 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 Engine ground: #2 (E16) No. 1 Engine ground: #3 (E6) No. 1 Engine ground: #4 (E17) No. 1 Engine ground: #5 (E43) No. 1 Engine ground: #6 (E44) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. Measure the resistance of harness between ECM and fuel injector on faulty cylinders. Connector & terminal #1 (B137) No. 8 (E5) No. 1: #2 (B137) No. 9 (E16) No. 1: #3 (B137) No. 10 (E6) No. 1: #4 (B137) No. 11 (E17) No. 1: #5 (B137) No. 12 (E43) No. 1: #6 (B137) No. 13 (E44) No. 1: CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground (): #5 (E43) No. 2 (+) Engine ground (): #6 (E44) No. 2 (+) Engine ground (): Check Is the voltage 10 V or more? Yes Go to step 6. No Go to step 2.
Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector Replace the faulty fuel injector. <Ref. to FU(H6DO)-28, Fuel Injector.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the main relay and fuel injector on faulty cylinders Poor contact of coupling connector Poor contact of main relay connector
EN(H6DO)(diag)-211

Step CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): #5 (B137) No. 12 (+) Chassis ground (): #6 (B137) No. 13 (+) Chassis ground (): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. CHECK CRANK PLATE. Check Is the voltage 10 V or more? Yes No Go to step 7. Repair the short circuit to power in the harness between the ECM and fuel injector.
Is the resistance less than 1 :? Replace the faulty Go to step 8. fuel injector. <Ref. to FU(H6DO)-28, Fuel Injector.>
10
11
CHECK INSTALLATION CONDITION OF TIMING CHAIN. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 18252AA000 CRANKSHAFT SOCKET CHECK FUEL LEVEL.
Is the camshaft position sensor Tighten the cam- Go to step 9. shaft position senor crankshaft position sensor sor or crankshaft loosely installed? position sensor. Is the crank sprocket rusted or Replace the crank Go to step 10. the teeth of crank plate broken? plate. <Ref. to ME(H6DO)-64, Cylinder Block.> Is the timing chain dislocated Correct the instal- Go to step 11. from its proper position? lation condition of timing chain. <Ref. to ME(H6DO)-46, Timing Chain Assembly.> Is the fuel meter indication lower than the Lower level? Refill the fuel so Go to step 12. that fuel meter indication is higher than the Lower level. After replenishing fuel, Go to step 13. Does the malfunction indicator Go to step 14. Go to step 13. light illuminate or blink?
12
CHECK STATUS OF MALFUNCTION INDICATOR LIGHT. 1) Clear the memory using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. 2) Start the engine, and drive the vehicle 10 minutes or more.
EN(H6DO)(diag)-212

13
14
15
16 17 18 19 20
CHECK MISFIRE SYMPTOM. 1) Turn the ignition switch to ON. 2) Read the DTC. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK FOR ANY OTHER DTC ON DISPLAY. Are DTCs P0301 and P0302 displayed? CHECK DTC ON DISPLAY. Are DTCs P0303 and P0304 displayed? CHECK DTC ON DISPLAY. Are DTC P0305 and P0306 displayed? CHECK DTC ON DISPLAY. Are DTC P0301, P0303 and P0305 displayed? CHECK DTC ON DISPLAY. Are DTC P0302, P0304 and P0306 displayed?
Go to step 22. Go to step 23. Go to step 24. Go to step 25. Go to step 26.
Go to step 17. Go to step 18. Go to step 19. Go to step 20. Go to step 27.
EN(H6DO)(diag)-213

Step ONLY ONE CYLINDER. Check Is there any fault in the cylinder? Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio No Check DTC P0171, P0172, P0174 or P0175 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Repair or replace Check DTC faulty parts. P0171, P0172, P0174 or P0175 NOTE: Check the fol- using List of Diagnostic Trouble lowing items. Code (DTC). Spark plug Fuel injector <Ref. to EN(H6DO)(diag) Ignition coil Compression 81, List of Diagnostic Trouble Code ratio If any fault is not (DTC).> found, check the IGNITION CONTROL SYSTEM of #1 and #2 cylinders side. <Ref. to EN(H6DO)(diag)73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> Repair or replace Check DTC faulty parts. P0171, P0172, P0174 or P0175 NOTE: Check the fol- using List of Diagnostic Trouble lowing items. Code (DTC). Spark plug Fuel injector <Ref. to EN(H6DO)(diag) Ignition coil Compression 81, List of Diagnostic Trouble Code ratio If any fault is not (DTC).> found, check the IGNITION CONTROL SYSTEM of #3 and #4 cylinders side. <Ref. to EN(H6DO)(diag)73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
21
22
23
EN(H6DO)(diag)-214

Step GROUP OF #5 AND #6 CYLINDERS. Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Ignition coil Compression ratio If any fault is not found, check the IGNITION CONTROL SYSTEM of #5 and #6 cylinders side. <Ref. to EN(H6DO)(diag)73, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> Is there any fault in #1, #3 and Repair or replace #5 cylinders? faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio Skipping timing chain teeth Is there any fault in #2, #4 and Repair or replace #6 cylinders? faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio Skipping timing chain teeth Is the engine idle rough? Check DTC P0171, P0172, P0174 or P0175 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Check Are there any faults in #5 and #6 cylinders? No Check DTC P0171, P0172, P0174 or P0175 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).>
24
25
GROUP OF #1, #3 AND #5 CYLINDERS.
Check DTC P0171, P0172, P0174 or P0175 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Check DTC P0171, P0172, P0174 or P0175 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio
26
GROUP OF #2, #4 AND #6 CYLINDERS.
27
CYLINDER AT RANDOM.
EN(H6DO)(diag)-215

BT:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-94, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance Knocking occurs. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
KNOCK SENSOR 2 (LH) KNOCK SENSOR 1 (RH)
1 2
E48
1 2 E14 E1 13 B20 15
E2 19 B21 14 16
29
B134
ECM
25
B21
E48 E14 B20 B134
1 2
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06875
EN(H6DO)(diag)-216

Replace the knock sensor. <Ref. to FU(H6DO)-23, Knock Sensor.>
EN(H6DO)(diag)-217

BU:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-95, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Poor driving performance Knocking occurs. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2
E48
1 2 E14 E1 13 B20 15
E2 19 B21 14 16
29
B134
ECM
25
B21
E48 E14 B20 B134
1 2
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06875
EN(H6DO)(diag)-218

EN(H6DO)(diag)-219

BV:DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-96, DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Driving performance problem Knocking is occurred. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2
E48
1 2 E14 E1 13 B20 15
E2 19 B21 14 16
29
B134
ECM
25
B21
E48 E14 B20 B134
1 2
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06875
EN(H6DO)(diag)-220

EN(H6DO)(diag)-221

BW:DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-96, DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Driving performance problem Knocking occurs. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2
E48
1 2 E14 E1 13 B20 15
E2 19 B21 14 16
29
B134
ECM
25
B21
E48 E14 B20 B134
1 2
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06875
EN(H6DO)(diag)-222

EN(H6DO)(diag)-223

BX:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-97, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E10 1 2
2 1
E10 B20
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
E1 8 7 B20 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
14 13 24 ECM
E
EN-03926
EN(H6DO)(diag)-224

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened securely? CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 and 1) Turn the ignition switch to OFF. 4 k:? 2) Remove the crankshaft position sensor. 3) Measure the resistance between connector terminals of crankshaft position sensor. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? CRANK SHAFT POSITION SENSOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between ECM and crankshaft position sensor connector. Connector & terminal (B134) No. 13 (E10) No. 1: (B134) No. 14 (E10) No. 2: Yes Go to step 2. No Tighten the crankshaft position sensor installation bolt securely. Replace the crankshaft position sensor. <Ref. to FU(H6DO)-21, Crankshaft Position Sensor.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and crankshaft position sensor connector Poor contact of coupling connector
Go to step 3.
EN(H6DO)(diag)-225

BY:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-99, DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
E10 1 2
2 1
E10 B20
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
E1 8 7 B20 1 8 9 18 19 28 29 2 10 20 30
B134 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B134
14 13 24 ECM
E
EN-03926
EN(H6DO)(diag)-226

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened Turn the ignition switch to OFF. securely? CHECK CRANKSHAFT PLATE. CHECK INSTALLATION CONDITION OF TIMING CHAIN. Turn the crankshaft, and align alignment mark on crank sprocket with alignment mark on cylinder block. ST 18252AA000 CRANKSHAFT SOCKET Are the crankshaft plate teeth cracked or damaged? Is the timing chain dislocated from its proper position? No Tighten the crankshaft position sensor installation bolt securely. Replace the crank- Go to step 3. shaft plate. Correct the instal- Replace the cranklation condition of shaft position sentiming chain. <Ref. sor. <Ref. to to ME(H6DO)-46, FU(H6DO)-21, Timing Chain Crankshaft PosiAssembly.> tion Sensor.> Yes Go to step 2.
2 3
EN(H6DO)(diag)-227

BZ:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-101, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 SBF-7 6 4 2 1 B47 CAMSHAFT POSITION SENSOR LH CAMSHAFT POSITION SENSOR RH BATTERY
E74
2 E73 E1 2 1 B20 21 11
48
E2 6 B21 22
B134
ECM
E73 E74
B47
B20
B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2 3
1 3 5
2 4 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
EN-06876
EN(H6DO)(diag)-228

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E73) No. 1 (+) Engine ground (): Yes Go to step 2. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the ECM and camshaft position sensor connector Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.
Go to step 4.
Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector. Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. <Ref. to Poor contact in ECM connector FU(H6DO)-22, Camshaft Position Poor contact of camshaft position Sensor.> sensor connector Poor contact of coupling connector
CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor. <Ref. to EN(H6DO)(diag)-17, Engine Control Module (ECM) I/O Signal.>
EN(H6DO)(diag)-229

CA:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-102, DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 SBF-7 6 4 2 1 B47 CAMSHAFT POSITION SENSOR LH CAMSHAFT POSITION SENSOR RH BATTERY
E74
2 E73 E1 2 1 B20 21 11
48
E2 6 B21 22
B134
ECM
E73 E74
B47
B20
B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2 3
1 3 5
2 4 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
1 8 9 18 19 28 29
2 10 20 30
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
EN-06876
EN(H6DO)(diag)-230

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E74) No. 1 (+) Engine ground (): Yes Go to step 2. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the ECM and camshaft position sensor connector Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.
Go to step 4.
Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector. Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. <Ref. to Poor contact in ECM connector FU(H6DO)-22, Camshaft Position Poor contact of camshaft position Sensor.> sensor connector Poor contact of coupling connector
CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor. <Ref. to EN(H6DO)(diag)-17, Engine Control Module (ECM) I/O Signal.>
EN(H6DO)(diag)-231

CB:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-103, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Movement performance problem when engine is low speed. Improper idling Movement performance problem CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY BATTERY SBF-7 6 4 B21 48 E2 B47 E76 10 E77
E18
1 2 3 4 5 6
B47 1 3 5 2 4 6
E77 1 2 3 4 6 5 7 9 10 8
EGR VALVE E18 B134 6 3 4 1 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
5 2 E77 6 4 7 3 E76 E2 22 32 33 21 B21
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
20 8 10 9 B134 ECM
EN-06877
EN(H6DO)(diag)-232

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK EGR VALVE. Remove the EGR valve. Check Yes No Is the measured value 53.3 kPa Make sure that the Go to step 2. (400 mmHg, 15.75 inHg) or EGR valve, manimore? fold absolute pressure sensor and throttle body are installed securely.
Are there holes, plugged piping Repair the EGR or foreign objects caught in the system. EGR system?
Replace the EGR valve. <Ref. to FU(H6DO)-27, EGR Valve.>
EN(H6DO)(diag)-233

CC:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-106, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine stalls. Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-234

Yes No Repair or replace Go to step 2. the exhaust system. <Ref. to EX(H6DO)-2, General Description.>
EN-06666

0.5 10 sec/div
EN-06667
EN(H6DO)(diag)-235

1
0 10 sec/div
EN-06668

1
0 10 sec/div
EN-06669

1
0 10 sec/div
EN-06670
Is the catalytic converter dam- Replace the cataaged? lytic converter. <Ref. to EC(H6DO)-3, Front Catalytic Converter.> CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside.
Go to step 5.
Go to step 6.
EN(H6DO)(diag)-236

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 7. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E61) No. 3: (B135) No. 30 (E61) No. 4: (B135) No. 15 (E25) No. 3: (B135) No. 30 (E25) No. 4: CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) Chassis ground (): (E25) No. 3 (+) Chassis ground (): Is the voltage 0.2 0.5 V? Go to step 8. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Repair the harness and connector. NOTE: Repair the following locations. Open circuit of harness between the ECM and rear oxygen sensor Poor contact in ECM and rear oxygen sensor Poor contact in ECM connector Repair the open circuit in the rear oxygen sensor harness.
Replace the rear oxygen sensor. <Ref. to FU(H6DO)-34, Rear Oxygen Sensor.>
EN(H6DO)(diag)-237

CD:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-108, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY SBF-7 5 3 6 4 2 1 B47 C17 C28 D29 BATTERY
C:
B136
D:
B137
ECM
14
15
B97 48 41 2 E77 E4 1 2 R1 B21 E2 R46 6 R67 R15 E76 10 R213
R144 2 1 1 2
5 R68
DRAIN VALVE
R144 1 2
E77 1 2 3 4 5 6
B47
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 C: B136 5 6 14 15 16 25 26 27 33 34 35 D: B137
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 3 5
2 4 6
E4 R68 R67 1 2 3 4 5 6 R213 1 2 3 4 5 6 7 8 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06878
EN(H6DO)(diag)-238

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H6DO)-52, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H6DO)-16, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: The drain valve can be operated using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H6DO)-8, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)53, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H6DO)-13, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 1.0 mm (0.04 in) dia. on evapo- the evaporation 1) Turn the ignition switch to OFF. ration line? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H6DO)-65, tor. Fuel Delivery and Evaporation Lines.>
EN(H6DO)(diag)-239

Step CHECK CANISTER. Yes Repair or replace the canister. <Ref. to EC(H6DO)-6, Canister.> Is the fuel tank damaged or is Repair or replace there any hole of more than the fuel tank. <Ref. to FU(H6DO)-45, 1.0 mm (0.04 in) dia. in it? Fuel Tank.> Is there any hole of more than Repair or replace 1.0 mm (0.04 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system? Check Is the canister damaged or is there a hole of more than 1.0 mm (0.04 in) dia. in it? No Go to step 9.
CHECK FUEL TANK. Remove the fuel tank. <Ref. to FU(H6DO)-45, Fuel Tank.> CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.
Go to step 10.
10
EN(H6DO)(diag)-240

CE:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-124, DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY SBF-7 5 3 6 4 2 1 B47 B97
MAIN RELAY
7 R1 R46
6 R67
1 2 R144
DRAIN VALVE CANISTER
R213 1 R15 R1 14 B97 B136 ECM 17
R144 1 2
B47
R67 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
R213 1 2 3 4 5 6 7 8
1 3 5
2 4 6
EN-05232
EN(H6DO)(diag)-241

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 17 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Measure the resistance between the drain valve connector and chassis ground. Connector & terminal (R144) No. 2 Chassis ground: CHECK HARNESS BETWEEN ECM AND DRAIN VALVE. Measure the resistance of harness between ECM and drain valve connector. Connector & terminal (B136) No. 17 (R144) No. 2: Check Is the voltage 10 V or more? Yes No Check for poor Go to step 2. contact of the ECM connector.
Go to step 3.
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and drain valve connector Poor contact of coupling connector Replace the drain valve. <Ref. to EC(H6DO)-16, Drain Valve.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between main relay and drain valve Poor contact of coupling connector Poor contact of main relay connector
EN(H6DO)(diag)-242

CF:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-126, DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY SBF-7 5 3 6 4 2 1 B47 B97
MAIN RELAY
7 R1 R46
6 R67
1 2 R144
R213 1 R15 R1 14 B97 B136 ECM 17
R144 1 2
B47
R67 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
R213 1 2 3 4 5 6 7 8
1 3 5
2 4 6
EN-05232
EN(H6DO)(diag)-243

Replace the drain valve. <Ref. to EC(H6DO)-16, Drain Valve.>
EN(H6DO)(diag)-244

CG:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-128, DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* * *
B83
22
32
B135 ECM
30
R47
R213 1 2 3 4 5 6 7 8
B83
1 2 3 4 5 6 7 8
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3
EN-05233
EN(H6DO)(diag)-245

Step CHECK FUEL FILLER CAP. 1) Turn the ignition switch to OFF. 2) Open the fuel flap. CHECK PRESSURE VACUUM LINE. NOTE: Check the following items. Disconnection, leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank Disconnection, leakage and clogging of the air ventilation hoses and pipes between fuel filler pipe and fuel tank Check Is the fuel filler cap tightened securely? Is there any fault in pressure/ vacuum line? Yes Go to step 2. No Tighten fuel filler cap securely. Replace the fuel tank pressure sensor. <Ref. to EC(H6DO)-12, Fuel Tank Pressure Sensor.>
EN(H6DO)(diag)-246

CH:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-130, DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* * *
B83
22
32
B135 ECM
30
R47
R213 1 2 3 4 5 6 7 8
B83
1 2 3 4 5 6 7 8
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3
EN-05233
EN(H6DO)(diag)-247

Step CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK FUEL TANK PRESSURE SENSOR POWER SOURCE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the fuel tank pressure sensor connector and chassis ground. Connector & terminal (R47) No. 3 (+) Chassis ground (): Check Yes Is the measured value less than Go to step 2. 7.45 kPa (55.85 mmHg, 2.2003 inHg) ? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact in ECM connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel tank pressure sensor connector. Replace the fuel tank pressure sensor. <Ref. to EC(H6DO)-12, Fuel Tank Pressure Sensor.>
Go to step 3.
Go to step 5.
EN(H6DO)(diag)-248

CI: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-132, DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 R47 R213 4 R15 R1 13 B97
7 6
17
* * *
B83
22
32
B135 ECM
30
R47
R213 1 2 3 4 5 6 7 8
B83
1 2 3 4 5 6 7 8
B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3
EN-05233
EN(H6DO)(diag)-249

Step CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel tank pressure sensor connector and engine ground. Connector & terminal (R47) No. 1 Engine ground: Check Yes Is the measured value 7.98 kPa Go to step 2. (59.85 mmHg, 2.357 inHg) or more? No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Go to step 3.
Is the measured value 7.98 kPa Repair the short (59.85 mmHg, 2.357 inHg) or circuit to power more? supply in the harness between the ECM and fuel tank pressure sensor connector.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel tank pressure sensor connector Poor contact in ECM connector Poor contact of coupling connector CHECK POOR CONTACT. Is there poor contact in fuel tank Repair the poor Replace the fuel Check for poor contact of the fuel tank pressure pressure sensor connector? contact in the fuel tank pressure sensensor connector. tank pressure sensor. <Ref. to EC(H6DO)-12, sor connector. Fuel Tank Pressure Sensor.>
EN(H6DO)(diag)-250

CJ:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-133, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 48 41 2 E77 E4 1 2 R1 B21 E2 R46 6 R67 R15 E76 10 R213
R144 2 1 1 2
5 R68
DRAIN VALVE
R144 1 2
E77 1 2 3 4 5 6
B47
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 C: B136 5 6 14 15 16 25 26 27 33 34 35 D: B137
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 3 5
2 4 6
E4 R68 R67 1 2 3 4 5 6 R213 1 2 3 4 5 6 7 8 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06878
EN(H6DO)(diag)-251

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H6DO)-52, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H6DO)-16, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H6DO)-8, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)53, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H6DO)-13, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 0.5 mm (0.020 in) dia. on evap- the evaporation 1) Turn the ignition switch to OFF. oration line? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H6DO)-65, tor. Fuel Delivery and Evaporation Lines.>
EN(H6DO)(diag)-252

Step CHECK CANISTER. Check Is the canister damaged or is there a hole of more than 0.5 mm (0.020 in) dia. in it? Is the fuel tank damaged or is there any hole of more than 0.5 mm (0.020 in) dia. in it? Is there any hole of more than 0.5 mm (0.020 in) dia., crack, clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system? Yes Repair or replace the canister. <Ref. to EC(H6DO)-6, Canister.> Repair or replace the fuel tank. <Ref. to FU(H6DO)-45, Fuel Tank.> Repair or replace the hoses or pipes. No Go to step 9.
Go to step 10.
10
EN(H6DO)(diag)-253

CK:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-133, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Fuel odor Fuel filler cap loose or lost CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
C:
B136
D:
B137
ECM
14
15
B97 48 41 2 E77 E4 1 2 R1 B21 E2 R46 6 R67 R15 E76 10 R213
R144 2 1 1 2
5 R68
DRAIN VALVE
R144 1 2
E77 1 2 3 4 5 6
B47
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 C: B136 5 6 14 15 16 25 26 27 33 34 35 D: B137
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 3 5
2 4 6
E4 R68 R67 1 2 3 4 5 6 R213 1 2 3 4 5 6 7 8 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06878
EN(H6DO)(diag)-254

Go to step 3.
Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe. <Ref. to FU(H6DO)-52, Fuel Filler Pipe.> CHECK DRAIN VALVE. Does the drain valve operate? Go to step 5. Replace the drain 1) Connect the delivery (test) mode connector. valve. <Ref. to 2) Turn the ignition switch to ON. EC(H6DO)-16, 3) Operate the drain valve using the Subaru Drain Valve.> Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK PURGE CONTROL SOLENOID Does the purge control soleGo to step 6. Replace the purge VALVE. noid valve operate? control solenoid Operate the purge control solenoid valve using valve. <Ref. to the Subaru Select Monitor. EC(H6DO)-8, Purge Control NOTE: Solenoid Valve.> Purge control solenoid valve operation can be executed using Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)53, Compulsory Valve Operation Check Mode.> CHECK PRESSURE CONTROL SOLENOID Does the pressure control sole- Go to step 7. Replace the presVALVE. noid valve operate? sure control soleOperate the pressure control solenoid valve noid valve. <Ref. to using the Subaru Select Monitor. EC(H6DO)-13, Pressure Control NOTE: Solenoid Valve.> The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.> CHECK EVAPORATIVE EMISSION CONAre there any disconnected, Repair or replace Go to step 8. TROL SYSTEM LINE. broken or clogged evaporation the evaporation 1) Turn the ignition switch to OFF. lines? line. <Ref. to 2) Disconnect the delivery (test) mode connecFU(H6DO)-65, tor. Fuel Delivery and Evaporation Lines.>
EN(H6DO)(diag)-255

Step CHECK CANISTER. Check Is the canister damaged? Yes Repair or replace the canister. <Ref. to EC(H6DO)-6, Canister.> Repair or replace the fuel tank. <Ref. to FU(H6DO)-45, Fuel Tank.> Repair or replace the hoses or pipes. No Go to step 9.
Go to step 10.
10
EN(H6DO)(diag)-256

CL:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-134, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 SBF-7 6 4 2 1 B47 B47
BATTERY E4 1 2
1 3 5
2 4 6
B137
ECM
E77
1 2 3 4 5 6 7 10 8 9
29
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 48 41 B21 E2
B21
E76 10 2 E77
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E4
1 2
EN-06879
EN(H6DO)(diag)-257

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground (): CHECK IN HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Measure the resistance between the purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 2 Engine ground: CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE. Measure the resistance of harness between ECM and purge control solenoid valve connector. Connector & terminal (B137) No. 29 (E4) No. 2: Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Go to step 5.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and purge control solenoid valve connector Poor contact of coupling connector Replace the purge control solenoid valve. <Ref. to EC(H6DO)-8, Purge Control Solenoid Valve.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between main relay and purge control solenoid valve connector Poor contact of coupling connector Poor contact of main relay connector
EN(H6DO)(diag)-258

CM:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-136, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 5 3 SBF-7 6 4 2 1 B47 B47
BATTERY E4 1 2
1 3 5
2 4 6
B137
ECM
E77
1 2 3 4 5 6 7 10 8 9
29
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31 48 41 B21 E2
B21
E76 10 2 E77
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E4
1 2
EN-06879
EN(H6DO)(diag)-259

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? PURGE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground (): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 :? VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 No. 2: Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and purge control solenoid valve connector.
Replace the purge Repair the poor control solenoid contact of ECM valve. <Ref. to connector. EC(H6DO)-8, Purge Control Solenoid Valve.>
EN(H6DO)(diag)-260

CN:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-138, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> No Replace the fuel level sensor and fuel sub level sensor. <Ref. to FU(H6DO)-57, Fuel Level Sensor.> <Ref. to FU(H6DO)-58, Fuel Sub Level Sensor.>
CO:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

NOTE: For the diagnostic procedure, refer to DTC P0463. <Ref. to EN(H6DO)(diag)-261, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CP:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-142, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0462 or P0463 displayed on the Subaru Select Monitor? Yes Check the combination meter. <Ref. to IDI-5, INSPECTION, Combination Meter System.> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
EN(H6DO)(diag)-261

CQ:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-144, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step Check Yes CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0464 displayed on the Check the combidisplay? nation meter. <Ref. to IDI-5, INSPECTION, Combination Meter System.> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
CR:DTC P0500 VEHICLE SPEED SENSOR A

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-147, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step CHECK DTC OF VDC. Check DTC of VDC. Check Is DTC of VDC displayed? Yes No Perform the diag- Repair the poor nosis according to contact of ECM DTC. <Ref. to connector. VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-262

CS:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-148, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Hard to start the engine. Engine does not start. Improper idling Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-06873
EN(H6DO)(diag)-263

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Is the air cleaner element Replace the air excessively clogged? cleaner element. <Ref. to IN(H6DO)-4, Air Cleaner Element.> Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control. No Go to step 2.
CHECK AIR CLEANER ELEMENT. 1) Turn the ignition switch to OFF. 2) Check the air cleaner element.
Go to step 3.
CHECK ELECTRONIC THROTTLE CONTROL. 1) Remove the electronic throttle control. 2) Check the electronic throttle control.
Perform the diagnosis of DTC P2101. <Ref. to EN(H6DO)(diag)324, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-264

CT:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-149, DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06873
EN(H6DO)(diag)-265

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Repair air suction Go to step 3. and leaks.
CHECK AIR INTAKE SYSTEM. 1) Start and idle the engine. 2) Check the following items. Loose installation of intake manifold and throttle body Cracks of intake manifold gasket and throttle body gasket Disconnection of vacuum hoses CHECK ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control. 3) Check the electronic throttle control.
Perform the diagnosis of DTC P2101. <Ref. to EN(H6DO)(diag)324, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-266

CU:DTC P0512 STARTER REQUEST CIRCUIT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-150, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
IGNITION SWITCH B72 BATTERY SBF-6 3 2 MAIN SBF
No.21
11
INHIBITOR RELAY B226 10 7
STARTER RELAY B225 16 14 STARTER MOTOR
TCM
11 B55 31 32 20 B14 ECM B136
15
13
B226
B72 1 2 3 4 5 6
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 3 5 7 2 4 6 8 25 26 27 28 9 10 11 12
B225 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4
7 8 9 10 5 11 6
EN-05651
EN(H6DO)(diag)-267

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Repair the short circuit to power in the harness between the ECM and ignition switch. No Go to step 2.
CV:DTC P0600 SERIAL COMMUNICATION LINK

EN(H6DO)(diag)-268

CW:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-154, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine does not start. Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B72
BATTERY
B21 37 35 34 52 36 E2
B21 B72 B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47 1 8 9 18 19 28 29
A: 2 10 20 30
B134
B:
B135
1 2 3 4 5 6
3 4 5 6 7 11 12 13 14 15 17 16 21 22 23 24 25 27 26 34 33 31 32 B136 5 6 16 14 15 27 25 26 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137
C:
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06864
EN(H6DO)(diag)-269

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
CX:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
NOTE: For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H6DO)(diag)-271, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-270

CY:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-156, DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
MAIN RELAY 3 5 6 4 2 1 B47 No. 12 1 C23 B2 A7 B5 B19 3 IGNITION SWITCH SBF-6 MAIN SBF TO OXYGEN SENSOR SBF-5 SBF-7 No. 13 B72 BATTERY
ECM A: B134 D3 D2 A3 D1 D7 A5 B: B135 C: B136 D: B137 A28 A18
A19 D4 D5 A29
E
B122
C6
37 35 34
52 36
20 39 38 19
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
A: B134
B72 1 2 3 4 5 6 B47 1 3 5 2 4 6 B122 1 2 3 4 5 6 7 8 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
E57
B20
C: B136
D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30
EN-06880
EN(H6DO)(diag)-271

Step Check Yes CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 13 V? Go to step 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. Is the voltage 13 15 V? Go to step 3. 1) Start the engine. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) Chassis ground (): (B135) No. 2 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 19 (E57) No. 5: (B134) No. 29 (E57) No. 3: No Repair the open or ground short circuit of power supply circuit.
CHECK ECM GROUND HARNESS. Is the voltage less than 1 V? Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 3 (+) Chassis ground (): (B134) No. 5 (+) Chassis ground (): (B137) No. 1 (+) Chassis ground (): (B137) No. 2 (+) Chassis ground (): (B137) No. 3 (+) Chassis ground (): (B137) No. 7 (+) Chassis ground ():
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the following item. Open circuit of ground circuit Retightening of engine ground terminals Poor contact of coupling connector
CZ:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)

NOTE: For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H6DO)(diag)-324, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
DA:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

EN(H6DO)(diag)-272

DB:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-162, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-273

Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Repair the poor Replace the front contact of the front oxygen (A/F) senoxygen (A/F) sensor. <Ref. to sor connector. FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
EN(H6DO)(diag)-274

DC:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-164, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-275

Go to step 5.
Go to step 4.
Repair the short circuit to power in the harness between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
Replace the front oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.> Repair the poor contact of ECM connector.
EN(H6DO)(diag)-276

DD:DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-166, DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-277

Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact of coupling connector Repair the poor Replace the front contact of the front oxygen (A/F) senoxygen (A/F) sensor. <Ref. to sor connector. FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
EN(H6DO)(diag)-278

DE:DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1)

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-166, DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-279

Go to step 5.
Go to step 4.
Repair the short circuit to power in the harness between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
Replace the front oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.> Repair the poor contact of ECM connector.
DF:DTC P1160 RETURN SPRING FAILURE

EN(H6DO)(diag)-280

DG:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-169, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY MAIN RELAY 5 3 6 4 2 1 B47 PRESSURE CONTROL SOLENOID VALVE SBF-7
2 R68 R213 5 R15 R1 15 B97 ECM 28
R67 R46 6 B136 7
R68
B47
R213 1 2 3 4 5 6 7 8
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2
1 3 5
2 4 6
R67 1 2 3 4 5 6
EN-05238
EN(H6DO)(diag)-281

Go to step 3.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and pressure control solenoid valve connector Poor contact of coupling connector Replace the presCHECK PRESSURE CONTROL SOLENOID Is the resistance between 10 Go to step 5. 100 :? sure control soleVALVE. noid valve. <Ref. to Measure the resistance between pressure conEC(H6DO)-13, trol solenoid valve terminals. Pressure Control Terminals Solenoid Valve.> No. 1 No. 2: CHECK POWER SUPPLY TO THE PRESIs the voltage 10 V or more? Repair the poor Repair the harness SURE CONTROL SOLENOID VALVE. contact of pressure and connector. 1) Turn the ignition switch to ON. control solenoid NOTE: 2) Measure the voltage between pressure convalve connector. In this case, repair trol solenoid valve and chassis ground. the following item: Connector & terminal Open circuit in (R68) No. 1 (+) Chassis ground (): harness between main relay and pressure control solenoid valve connector Poor contact of coupling connector Poor contact of main relay connector
EN(H6DO)(diag)-282

DH:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-171, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY MAIN RELAY 5 3 6 4 2 1 B47 PRESSURE CONTROL SOLENOID VALVE SBF-7
2 R68 R213 5 R15 R1 15 B97 ECM 28
R67 R46 6 B136 7
R68
B47
R213 1 2 3 4 5 6 7 8
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2
1 3 5
2 4 6
R67 1 2 3 4 5 6
EN-05238
EN(H6DO)(diag)-283

Is the resistance less than 1 :? Replace the pres- Repair the poor sure control sole- contact of ECM noid valve. <Ref. to connector. EC(H6DO)-13, Pressure Control Solenoid Valve.>
EN(H6DO)(diag)-284

DI: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-173, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper fuel supply CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
BATTERY SBF-7 5 3 6 4 2 1 B47 B97
MAIN RELAY
7 R1 R46
6 R67
1 2 R144
R213 1 R15 R1 14 B97 B136 ECM 17
R144 1 2
B47
R67 1 2 3 4 5 6
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
R213 1 2 3 4 5 6 7 8
1 3 5
2 4 6
EN-05232
EN(H6DO)(diag)-285

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check the appropriate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Replace the drain hose. Repair the poor contact of ECM connector. No Go to step 2.
2 3
CHECK DRAIN HOSE. Is there clogging in the drain Check the drain hose for clogging. hose? CHECK DRAIN VALVE OPERATION. Does the drain valve operate? 1) Turn the ignition switch to OFF. 2) Connect the delivery (test) mode connector at the lower portion of instrument panel (on the drivers side). 3) Turn the ignition switch to ON. 4) Operate the drain valve. NOTE: Drain valve can be operated using the Subaru Select Monitor. For the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H6DO)(diag)-53, Compulsory Valve Operation Check Mode.>
Go to step 3. Replace the drain valve. <Ref. to EC(H6DO)-16, Drain Valve.>
EN(H6DO)(diag)-286

DJ:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
NOTE: For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H6DO)(diag)-288, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
DK:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
NOTE: For the diagnostic procedure, refer to DTC P1499. <Ref. to EN(H6DO)(diag)-291, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
DL:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
DM:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
DN:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
DO:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
EN(H6DO)(diag)-287

DP:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-175, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine breathing CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
EN(H6DO)(diag)-288

WIRING DIAGRAM:
E18
1 2 3 4 5 6
B47 1 3 5 2 4 6
E77 1 2 3 4 6 5 7 9 10 8
EGR VALVE E18 B134 6 3 4 1 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
5 2 E77 6 4 7 3 E76 E2 22 32 33 21 B21
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
20 8 10 9 B134 ECM
EN-06877
EN(H6DO)(diag)-289

Step Check CHECK POWER SUPPLY TO EGR VALVE. Is the voltage 10 V or more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between EGR valve connector and engine ground. Connector & terminal (E18) No. 2 (+) Engine ground (): (E18) No. 5 (+) Engine ground (): Yes Go to step 2. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between EGR valve connector and main relay connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and EGR valve connector Poor contact of coupling connector Repair the ground short in harness between ECM and EGR valve connector.
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 3. EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance of harness between ECM and EGR valve connector. Connector & terminal DTC P1492; (B134) No. 8 (E18) No. 3: DTC P1494; (B134) No. 9 (E18) No. 1: DTC P1496; (B134) No. 10 (E18) No. 4: DTC P1498; (B134) No. 20 (E18) No. 6: CHECK HARNESS BETWEEN ECM AND EGR VALVE CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal DTC P1492; (B134) No. 8 Chassis ground: DTC P1494; (B134) No. 9 Chassis ground: DTC P1496; (B134) No. 10 Chassis ground: DTC P1498; (B134) No. 20 Chassis ground: CHECK POOR CONTACT. Check poor contact of ECM and EGR valve connectors. Is the resistance 1 M: or more? Go to step 4.
Is there poor contact in ECM or Repair the poor EGR valve connector? contact in ECM or EGR valve connector.
Replace the EGR valve. <Ref. to FU(H6DO)-27, EGR Valve.>
EN(H6DO)(diag)-290

DQ:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-177, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine breathing CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
EN(H6DO)(diag)-291

WIRING DIAGRAM:
E18
1 2 3 4 5 6
B47 1 3 5 2 4 6
E77 1 2 3 4 6 5 7 9 10 8
EGR VALVE E18 B134 6 3 4 1 1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
5 2 E77 6 4 7 3 E76 E2 22 32 33 21 B21
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
20 8 10 9 B134 ECM
EN-06877
Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal DTC P1493; (B134) No. 8 (+) Chassis ground (): DTC P1495; (B134) No. 9 (+) Chassis ground (): DTC P1497; (B134) No. 10 (+) Chassis ground (): DTC P1499; (B134) No. 20 (+) Chassis ground ():
Yes No Repair the power Repair the poor supply short circuit contact of ECM of harness connector. between ECM and EGR valve connector.
EN(H6DO)(diag)-292

DR:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-180, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B72
BATTERY
B21 37 35 34 52 36 E2
B21 B72 B47 1 3 5 2 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47 1 8 9 18 19 28 29
A: 2 10 20 30
B134
B:
B135
1 2 3 4 5 6
3 4 5 6 7 11 12 13 14 15 17 16 21 22 23 24 25 27 26 34 33 31 32 B136 5 6 16 14 15 27 25 26 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137
C:
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06864
EN(H6DO)(diag)-293

Step CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 5 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR. 1) Disconnect the connectors from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 5 Chassis ground: CHECK FUSE NO. 13. Check Is the voltage 10 V or more? Yes Repair the poor contact of ECM connector. No Go to step 2.
Go to step 3.
Replace the fuse.
EN(H6DO)(diag)-294

DS:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-182, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. Engine keeps running at a lower speed than the specified idle speed. Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
10
12
11
13 47 E43 2 1 B21 E2 E44
48
42
43
44
E5 2 1 2 1
E16 2 1
E6 2 1
45
E17 2 1
46
E
E43 E5 E6 1 2
E44 E16 E17
B47 1 3 5 2 4 6
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06776
EN(H6DO)(diag)-295

4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06873
Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?
CHECK ENGINE OIL.
Are there holes or loose bolts on exhaust system?
Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Go to step 3. Replace engine oil. <Ref. to LU(H6DO)-8, REPLACEMENT, Engine Oil.> Repair the exhaust Go to step 4. system.
EN(H6DO)(diag)-296

Check Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 333 363 kPa (3.4 3.7 kgf/cm2, WARNING: Place NO OPEN FLAMES signs near the 48 53 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. <Ref. to ME(H6DO)-27, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant temperaSENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value 2.0 TEMPERATURE SENSOR. 5.0 g/s (0.26 0.66 lb/m)? 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Step CHECK AIR INTAKE SYSTEM. Yes Repair the air intake system. Go to step 6. No Go to step 5.
Repair the following item. Fuel pressure is too high: Clogged fuel line or bent hose Fuel pressure is too low: Improper fuel pump discharge Clogged fuel line Replace the engine coolant temperature sensor. <Ref. to FU(H6DO)-20, Engine Coolant Temperature Sensor.>
Go to step 7.
Go to step 8.
EN(H6DO)(diag)-297

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): #5 (B137) No. 12 (+) Chassis ground (): #6 (B137) No. 13 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 Engine ground: #2 (E16) No. 1 Engine ground: #3 (E6) No. 1 Engine ground: #4 (E17) No. 1 Engine ground: #5 (E43) No. 1 Engine ground: #6 (E44) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. Measure the resistance of harness between ECM and fuel injector on faulty cylinders. Connector & terminal #1 (B137) No. 8 (E5) No. 1: #2 (B137) No. 9 (E16) No. 1: #3 (B137) No. 10 (E6) No. 1: #4 (B137) No. 11 (E17) No. 1: #5 (B137) No. 12 (E43) No. 1: #6 (B137) No. 13 (E44) No. 1: Check Yes Subtract ambient temperature Go to step 9. from intake air temperature. Is the obtained value 10 50C (18 90F)? No Check the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.>
Go to step 14.
Go to step 10.
10
Go to step 11.
11
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and fuel injector connector Poor contact of coupling connector
EN(H6DO)(diag)-298

Step CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground (): #5 (E43) No. 2 (+) Engine ground (): #6 (E44) No. 2 (+) Engine ground (): Check Yes Is the resistance between 5 Go to step 13. 20 :? No Replace the faulty fuel injector. <Ref. to FU(H6DO)-28, Fuel Injector.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between the main relay and fuel injector on faulty cylinders Poor contact of coupling connector Poor contact of main relay connector Go to step 15.
12
13
14
15
16
CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 8 (+) Chassis ground (): #2 (B137) No. 9 (+) Chassis ground (): #3 (B137) No. 10 (+) Chassis ground (): #4 (B137) No. 11 (+) Chassis ground (): #5 (B137) No. 12 (+) Chassis ground (): #6 (B137) No. 13 (+) Chassis ground (): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. CHECK CRANK PLATE.
Repair the short circuit to power in the harness between the ECM and fuel injector.
Is the resistance less than 1 :? Replace the faulty Go to step 16. fuel injector. <Ref. to FU(H6DO)-28, Fuel Injector.>
17
18
CHECK INSTALLATION CONDITION OF TIMING CHAIN. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 18252AA000 CRANKSHAFT SOCKET
Is the camshaft position sensor Tighten the cam- Go to step 17. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 18. the teeth of crank plate broken? plate. <Ref. to ME(H6DO)-64, Cylinder Block.> Is the timing chain dislocated Correct the instal- Go to step 19. lation condition of from its proper position? timing chain. <Ref. to ME(H6DO)-46, Timing Chain Assembly.>
EN(H6DO)(diag)-299

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 8 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 8: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: Check Yes Is the resistance less than 1 :? Go to step 20. No Replace the electronic throttle control relay. <Ref. to EN(H6DO)(diag)8, Electrical Component Location.>
19
20
Go to step 21.
21
22
Go to step 23.
23
24
Go to step 25.
EN(H6DO)(diag)-300

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 M: or 1) Connect the connector to ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Yes Go to step 26. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 29.
25
26
27
28
29
Go to step 30.
EN(H6DO)(diag)-301

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> CHECK SENSOR OUTPUT. Is the voltage 1.64 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> Yes Go to step 31. No Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H6DO)-13, Throttle Body.> Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H6DO)-13, Throttle Body.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control Poor contact of coupling connector Go to step 34.
30
31
Go to step 32.
32
33
34
Go to step 35.
35
Go to step 36.
EN(H6DO)(diag)-302

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers. Check Yes Is the resistance less than 5 :? Go to step 37. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the electronic throttle control. <Ref. to FU(H6DO)-13, Throttle Body.> Replace the electronic throttle control. <Ref. to FU(H6DO)-13, Throttle Body.>
36
37
38
EN(H6DO)(diag)-303

DT:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-184, DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM E67 1 2 17 16
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
23 24 B21 E2
34 42 48
35 43 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E67 1 2 OIL FLOW CONTROL SOLENOID VALVE RH
EN-06881
EN(H6DO)(diag)-304

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. FLOW CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve. Connector & terminal (B137) No. 17 (E67) No. 1: (B137) No. 16 (E67) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve connector. Replace the oil flow control solenoid valve. <Ref. to ME(H6DO)-55, Camshaft.>
Go to step 3.
EN(H6DO)(diag)-305

DU:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-185, DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM E67 1 2 17 16
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
23 24 B21 E2
34 42 48
35 43 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E67 1 2 OIL FLOW CONTROL SOLENOID VALVE RH
EN-06881
EN(H6DO)(diag)-306

Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector CHECK OIL FLOW CONTROL SOLENOID Replace the oil Is the resistance between 6 Repair the poor VALVE. flow control sole12 :? contact of ECM Measure the resistance between oil flow control and oil flow control noid valve. <Ref. to solenoid valve terminals. solenoid valve con- ME(H6DO)-55, Terminals Camshaft.> nector. No. 1 No. 2:
EN(H6DO)(diag)-307

DV:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-186, DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM E68 1 2 15 14
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
27 28 B21 E2
34 42 48
35 43 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E68 1 2 OIL FLOW CONTROL SOLENOID VALVE LH
EN-06882
EN(H6DO)(diag)-308

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 :? Go to step 2. FLOW CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve. Connector & terminal (B137) No. 15 (E68) No. 1: (B137) No. 14 (E68) No. 2: No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve connector. Replace the oil flow control solenoid valve. <Ref. to ME(H6DO)-55, Camshaft.>
Go to step 3.
EN(H6DO)(diag)-309

DW:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-186, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
B137 ECM E68 1 2 15 14
B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
27 28 B21 E2
34 42 48
35 43 49
36 50
37 44 51
38 45 52
39 53
40 46 54
41 47
E68 1 2 OIL FLOW CONTROL SOLENOID VALVE LH
EN-06882
EN(H6DO)(diag)-310

Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of the harness between the ECM and oil flow control solenoid valve connector Poor contact of coupling connector CHECK OIL FLOW CONTROL SOLENOID Replace the oil Is the resistance between 6 Repair the poor VALVE. flow control sole12 :? contact of ECM Measure the resistance between oil flow control and oil flow control noid valve. <Ref. to solenoid valve terminals. solenoid valve con- ME(H6DO)-55, Terminals Camshaft.> nector. No. 1 No. 2:
DX:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
NOTE: Refer to DTC P2097 for diagnostic procedure. <Ref. to EN(H6DO)(diag)-312, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-311

DY:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-189, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-312

14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-313

Yes No Check DTC using Go to step 2. List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> CHECK FRONT OXYGEN (A/F) SENSOR Has water entered the connec- Completely Go to step 3. CONNECTOR AND COUPLING CONNECtor? remove any water TOR. inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the harness FRONT OXYGEN (A/F) SENSOR CONNECand connector. TOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM and the following item: front oxygen (A/F) sensor. Open circuit in 3) Measure the resistance of harness between harness between ECM and front oxygen (A/F) sensor connector. ECM and front oxyConnector & terminal gen (A/F) sensor (B135) No. 9 (E47) No. 3: connector (B135) No. 8 (E47) No. 4: Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Go to step 5. Repair the ground FRONT OXYGEN (A/F) SENSOR CONNEC- more? short circuit of harTOR. ness between Measure the resistance between ECM and ECM and front oxychassis ground. gen (A/F) sensor Connector & terminal connector. (B135) No. 9 Chassis ground: (B135) No. 8 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.5 V or more? Go to step 7. Go to step 6. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E47) No. 3 (+) Chassis ground (): CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.95 V or more? Go to step 7. Go to step 8. Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E47) No. 4 (+) Chassis ground (): Repair the poor CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 8 V or more? Repair the short Measure the voltage between front oxygen (A/F) circuit to power in contact of ECM connector. sensor connector and chassis ground. the harness Connector & terminal between ECM and (E47) No. 3 (+) Chassis ground (): front oxygen (A/F) (E47) No. 4 (+) Chassis ground (): sensor connector. After repair, replace the ECM. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).> CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 9. on exhaust system? system. Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?
EN(H6DO)(diag)-314

Step CHECK AIR INTAKE SYSTEM. Check Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 333 343 kPa (3.4 3.5 kgf/cm2, WARNING: Place NO OPEN FLAMES signs near the 48.4 49.8 psi)? working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. <Ref. to ME(H6DO)-27, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant temperaSENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value 2.0 TEMPERATURE SENSOR. 5.0 g/s (0.26 0.66 lb/m)? 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Yes Repair the air intake system. Go to step 11. No Go to step 10.
10
11
Go to step 12.
12
Go to step 13.
EN(H6DO)(diag)-315

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value 10 50C (18 90F)? No Check the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.>
13
14
Go to step 16.
15
Go to step 16.
16
Has water entered the connec- Completely tor? remove any water inside.
Go to step 18.
EN(H6DO)(diag)-316

Step CHECK FRONT OXYGEN (A/F) SENSOR AND REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is higher than 75C (167F), then keep the engine idling for 5 minutes or more. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 4 (E61) No. 3: (B135) No. 30 (E61) No. 4: Check Is a voltage of 0.8 V or more maintained for 5 minutes or more? Yes No Replace the front Go to step 18. oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
17
18
19
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H6DO)-34, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact in ECM connector Poor contact of coupling connector
DZ:DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2
NOTE: Refer to DTC P2099 for diagnostic procedure. <Ref. to EN(H6DO)(diag)-318, DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-317

EA:DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2
DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-190, DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
8 E3
E
1 E3 4 B22
5 6
B138
B11 B10
B1
B7 B6
B8 B9
2 1 B21 E2
4 3
3 4
A: B134
B: B135
C: B136
D1 D7
D: B137
A5
ECM
37
35
D3 A3 D2
34
52
36
E24 E47 1 2 3 4
B47 1 3 5 2 4 6
A: B134
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 8 9 18 19 28 29 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
C2 C3
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B22
B138
1 2 3 4 5 6 7 8
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
EN-06867
EN(H6DO)(diag)-318

14 E3
E25
E61
E
E3 B22
*2
*1 *1 *1
B83
B138
*2
B15 B4
A: B134
B: B135 C: B136
D3 A3 D2 D1 D7
D: B137
A5
ECM
35
34
52
37
36
B21 E2
*1 *2
E25 1 2 3 4
E61
B47 1 3 5 2 4 6 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 D: B137 5 6 14 15 16 25 26 27 33 34 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
B30
C5
B1
C4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
B22 B83 B138 1 5 9 13 2 6 10 14 3 7 11 15 4 8 12 16
1 2 3 4 5 6 7 8
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
EN-06868
EN(H6DO)(diag)-319

Yes No Check DTC using Go to step 2. List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> CHECK FRONT OXYGEN (A/F) SENSOR Has water entered the connec- Completely Go to step 3. CONNECTOR AND COUPLING CONNECtor? remove any water TOR. inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 :? Go to step 4. Repair the harness FRONT OXYGEN (A/F) SENSOR CONNECand connector. TOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connectors from ECM and the following item: front oxygen (A/F) sensor. Open circuit in 3) Measure the resistance of harness between harness between ECM and front oxygen (A/F) sensor connector. ECM and front oxyConnector & terminal gen (A/F) sensor (B135) No. 11 (E24) No. 3: connector (B135) No. 10 (E24) No. 4: Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or Go to step 5. Repair the ground FRONT OXYGEN (A/F) SENSOR CONNEC- more? short circuit of harTOR. ness between Measure the resistance between ECM and ECM and front oxychassis ground. gen (A/F) sensor Connector & terminal connector. (B135) No. 11 Chassis ground: (B135) No. 10 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.5 V or more? Go to step 7. Go to step 6. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) Chassis ground (): CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 4.95 V or more? Go to step 7. Go to step 8. Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 4 (+) Chassis ground (): Repair the poor CHECK OUTPUT SIGNAL FOR ECM. Is the voltage 8 V or more? Repair the short Measure the voltage between front oxygen (A/F) circuit to power in contact of ECM connector. sensor connector and chassis ground. the harness Connector & terminal between ECM and (E24) No. 3 (+) Chassis ground (): front oxygen (A/F) (E24) No. 4 (+) Chassis ground (): sensor connector. After repair, replace the ECM. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).> CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 9. on exhaust system? system. Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?
EN(H6DO)(diag)-320

Step CHECK AIR INTAKE SYSTEM. Check Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 333 343 kPa (3.4 3.5 kgf/cm2, WARNING: Place NO OPEN FLAMES signs near the 48.4 49.8 psi)? working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. <Ref. to ME(H6DO)-27, INSPECTION, Fuel Pressure.> CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant temperaSENSOR. ture 75C (167F) or higher? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value 2.0 TEMPERATURE SENSOR. 5.0 g/s (0.26 0.66 lb/m)? 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. Yes Repair the air intake system. Go to step 11. No Go to step 10.
10
11
Go to step 12.
12
Go to step 13.
EN(H6DO)(diag)-321

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75C (167F). 2) Place the select lever in P range or N range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of the mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and keep the engine speed at 3,000 rpm. (for up to 2 minutes) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75C (167F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value 10 50C (18 90F)? No Check the mass air flow and intake air temperature sensor. <Ref. to FU(H6DO)-26, Mass Air Flow and Intake Air Temperature Sensor.>
13
14
Go to step 16.
15
Go to step 16.
16
Has water entered the connec- Completely tor? remove any water inside.
Go to step 18.
EN(H6DO)(diag)-322

Step CHECK FRONT OXYGEN (A/F) SENSOR AND REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is higher than 75C (167F), then keep the engine idling for 5 minutes or more. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: SUBARU SELECT MONITOR For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> General Scan Tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 15 (E25) No. 3: (B135) No. 30 (E25) No. 4: Check Is a voltage of 0.8 V or more maintained for 5 minutes or more? Yes No Replace the front Go to step 18. oxygen (A/F) sensor. <Ref. to FU(H6DO)-32, Front Oxygen (A/F) Sensor.>
17
18
19
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and rear oxygen sensor connector Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector. <Ref. to NOTE: FU(H6DO)-34, In this case, repair Rear Oxygen Sen- the following item: sor.> Open circuit of harness between the ECM and rear oxygen sensor Poor contact in ECM connector Poor contact of coupling connector
EN(H6DO)(diag)-323

EB:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-191, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27
EN-06873
EN(H6DO)(diag)-324

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 8 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 8: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: Check Yes Is the resistance less than 1 :? Go to step 2. No Replace the electronic throttle control relay. <Ref. to EN(H6DO)(diag)8, Electrical Component Location.>
Go to step 3.
Go to step 5.
Go to step 7.
EN(H6DO)(diag)-325

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 M: or 1) Connect the connector to ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Yes Go to step 8. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 11.
10
11
Go to step 12.
EN(H6DO)(diag)-326

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> CHECK SENSOR OUTPUT. Is the voltage 1.64 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.> Yes Go to step 13. No Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H6DO)-13, Throttle Body.> Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H6DO)-13, Throttle Body.> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control Poor contact of coupling connector Go to step 16.
12
13
Go to step 14.
14
15
16
Go to step 17.
17
Go to step 18.
EN(H6DO)(diag)-327

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: (B134) No. 5 Chassis ground: (B137) No. 1 Chassis ground: (B137) No. 2 Chassis ground: (B137) No. 3 Chassis ground: (B137) No. 7 Chassis ground: CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers. Check Yes Is the resistance less than 5 :? Go to step 19. No Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact of coupling connector Replace the electronic throttle control. <Ref. to FU(H6DO)-13, Throttle Body.> Replace the electronic throttle control. <Ref. to FU(H6DO)-13, Throttle Body.>
18
19
20
EN(H6DO)(diag)-328

EC:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-193, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance Engine stalls. CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06873
EN(H6DO)(diag)-329

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 5 and No. 6 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connectors from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 6 Chassis ground: (B362) No. 8 Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B136) No. 21 (B362) No. 6: (B136) No. 1 (B362) No. 8: Check Yes Is the resistance less than 1 :? Go to step 2. No Replace the electronic throttle control relay. <Ref. to EN(H6DO)(diag)8, Electrical Component Location.>
Go to step 3.
Go to step 5.
EN(H6DO)(diag)-330

ED:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-195, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06873
EN(H6DO)(diag)-331

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Measure the resistance between electronic throttle control relay terminals. Terminals No. 7 No. 8: CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUPPLY. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B362) No. 8 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 21 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Replace the electronic throttle control relay. <Ref. to EN(H6DO)(diag)8, Electrical Component Location.>
EE:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE

EN(H6DO)(diag)-332

EF:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-199, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 2 B122
B315
1 2 3 4 5 6 7 8
A: B134
1 8 9 18 19 28 29 B83 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
B21 B23 B29 B22 B31 B30 B122 A: B134 B: B135 C: B136 D: B137 ECM
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D1
C6
D3
A3
D2
D7
A5
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21 37 34 52 35 36 E2
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06883
EN(H6DO)(diag)-333

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 21 Chassis ground: (B135) No. 23 Chassis ground: (B135) No. 23 (B136) No. 6: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector.
Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
EN(H6DO)(diag)-334

EG:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-201, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 2 B122
B315
1 2 3 4 5 6 7 8
A: B134
1 8 9 18 19 28 29 B83 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D1
C6
D3
A3
D2
D7
A5
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21 37 34 52 35 36 E2
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06883
EN(H6DO)(diag)-335

EN(H6DO)(diag)-336

EH:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-203, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 2 B122
B315
1 2 3 4 5 6 7 8
A: B134
1 8 9 18 19 28 29 B83 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D1
C6
D3
A3
D2
D7
A5
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21 37 34 52 35 36 E2
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06883
EN(H6DO)(diag)-337

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 22 Chassis ground: (B135) No. 31 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 Chassis ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector.
Repair the ground short circuit of harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
EN(H6DO)(diag)-338

EI: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-205, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
1 2 3 4 5 6
B83 2 B122
B315
1 2 3 4 5 6 7 8
A: B134
1 8 9 18 19 28 29 B83 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D1
C6
D3
A3
D2
D7
A5
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21 37 34 52 35 36 E2
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06883
EN(H6DO)(diag)-339

EN(H6DO)(diag)-340

EJ:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-207, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> TROUBLE SYMPTOM: Improper idling Poor driving performance CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. WIRING DIAGRAM:
4 MAIN RELAY
6 B47
C1
ECM A: B134 C: B136 D: B137
E
A28 A18
A19 D4 D5 A29
D3 D2 A3 D1 D7 A5
C6
B122
20 39 38 19
37 35 34
52 36
B21 E2
16 15
B20 E1
* * *
5 1 2 3
4 6
B47 1 3 5 2 4 6
B122 1 2 3 4 5 6 7 8
B362 1 8 9 18 19 28 29 2 10 20 30
A: B134
3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
1 2
3 4
5 7 8 6 B20 E57
1 2 3 4 5 6
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
EN-06873
EN(H6DO)(diag)-341

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 Chassis ground: (B134) No. 18 Chassis ground: (B134) No. 18 (B136) No. 6: (B134) No. 28 Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 Engine ground: (E57) No. 4 Engine ground: Check Is the resistance 1 M: or more? Yes Go to step 2. No Repair the short circuit to ground in harness between ECM and electronic throttle control connector.
Go to step 3.
Repair the short circuit to ground in harness between ECM and electronic throttle control connector. Replace the ECM if defective. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).> Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit in harness between ECM and electronic throttle control connector Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector Go to step 6.
EN(H6DO)(diag)-342

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 M: or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 (B134) No. 18: (B134) No. 19 (B134) No. 28: Yes Repair poor contact of the electronic throttle control connector. Replace the electronic throttle control if defective. <Ref. to FU(H6DO)-13, Throttle Body.> No Repair the short circuit to power in the harness between ECM and electronic throttle control connector.
EN(H6DO)(diag)-343

EK:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-209, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>. TROUBLE SYMPTOM: Improper idling Poor driving performance WIRING DIAGRAM:
1 2 3 4 5 6
B83 2 B122
B315
1 2 3 4 5 6 7 8
A: B134
1 8 9 18 19 28 29 B83 2 10 20 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32
* *
* *
B: B135
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30 5 6 14 15 16 25 26 27 33 34 35
D1
C6
D3
A3
D2
D7
A5
D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31
B21 37 34 52 35 36 E2
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
EN-06883
EN(H6DO)(diag)-344

Step CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 23 (+) Chassis ground (): (B135) No. 31 (+) Chassis ground (): CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) Chassis ground (): (B315) No. 3 (+) Chassis ground (): Check Yes Is the difference in measured Go to step 3. values for the main accelerator pedal position sensor signal and the sub accelerator pedal position sensor signal 0 V? No Go to step 2.
Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and accelerator pedal position sensor connector. Short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: Open circuit of harness between the ECM and accelerator pedal position sensor connector. Open circuit of harness between ECM and engine ground Poor contact in ECM connector Poor contact of coupling connector
EN(H6DO)(diag)-345

EL:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE

DTC DETECTING CONDITION: Two consecutive driving cycles with fault GENERAL DESCRIPTION <Ref. to GD(H6DO)-211, DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
1 Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> No Replace the ECM. <Ref. to FU(H6DO)-38, Engine Control Module (ECM).> NOTE: The barometric pressure sensor is built into the ECM.
EM:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-212, DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
EN(H6DO)(diag)-346

EN:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH

DTC DETECTING CONDITION: Immediately at fault recognition GENERAL DESCRIPTION <Ref. to GD(H6DO)-213, DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode <Ref. to EN(H6DO)(diag)-52, OPERATION, Clear Memory Mode.>, and Inspection Mode <Ref. to EN(H6DO)(diag)-44, PROCEDURE, Inspection Mode.>.
EN(H6DO)(diag)-347


A: CHECK SI-DRIVE (SUBARU INTELLIGENT DRIVE) SYSTEM
DIAGNOSIS: SI-DRIVE mode will not change. CAUTION: Note that the SI-DRIVE system performs the following control when changing modes. 1. When the engine is cold, the low coolant temperature display will light in the multi-information display meter. In this case, it will not be possible to change to the S# (sports sharp) mode. 2. If the engine is stopped in the S# (sports sharp) mode, it will be in the S (sports) mode when the engine is restarted. 3. If the engine is stopped in the S (sports) or I (intelligent) mode, then restarted, it will enter the mode it was on before stopping the engine. 4. If the malfunction indicator light becomes lit while the engine is running, it will enter the S (sports) mode. In this case, it will not be possible to change to the S# (sports sharp) or I (intelligent) mode. 5. If there is a possible engine coolant or engine oil temperature overheat condition, it will not be possible to switch to the S# (sports sharp) mode. When driving in the S# (sports sharp) mode, it will enter the S (sports) mode.
EN(H6DO)(diag)-348

1. EVEN WHEN THE SI-DRIVE MODE IS CHANGED, THE MULTI-INFORMATION DISPLAY DOES NOT CHANGE, AND THE MODE DOES NOT SWITCH.
WIRING DIAGRAM:
COMBINATION METER A: B12 B9 i10 B8 B: i11 A11 i1 24 9 B36 B68 ST1 12 ROLL CONNECTOR 2 C7 3 ST4 3 4 ST5 4 B68 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B: i11 A12
i54 2 R99 1 16
R43 15 C1 5 5 I
S#
E
SI-DRIVE S# SWITCH
SI-DRIVE SELECTOR
C7 1 2 3 4 5
ST4 1 2 3 4 5 6
ST5 1 2 3 4 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 i1
i54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
R43 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A:
i10 6 7 8 9 10 17 18 19 20 21 22 3 4 1 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 11 12 13 14 15 16
EN-05720
EN(H6DO)(diag)-349

Step CHECK SI-DRIVE SELECTOR. 1) Disconnect the connector from the multiinformation display meter. 2) Measure the resistance between connectors when the SI-DRIVE selector is operated. Connector & terminal (i11) No. 9 (i11) No. 12: CHECK SI-DRIVE S# SWITCH. 1) Hold down the SI- DRIVE S# switch. 2) Measure the resistance of harness between the multi-information display meter connector and chassis ground. Connector & terminal (i11) No. 8 Chassis ground: CHECK POOR CONTACT. Check the following items. Cracked or improperly connected connector Broken connector pin Disconnection connector terminal RECHECK FAULT. 1) Connect all connectors. 2) Change the SI-DRIVE mode. Check Yes Does the resistance change as Go to step 2. shown below? S#: 2.14 3.2 k: I: 0.8 1.2 k: S: Less than 10 : No Go to step 5.
Go to step 6.
CHECK SI-DRIVE SELECTOR HARNESS AND CONNECTOR. Check the following items. Short or open circuit in the harness Improperly connected or loose terminal in the SI-DRIVE selector connector Improperly connected or loose terminal in coupling connector CHECK SI-DRIVE S# SWITCH HARNESS AND CONNECTOR. Check the following items. Short or open circuit in the harness Improperly connected or loose terminal in steering roll connector Improperly connected or loose terminal in coupling connector RECHECK FAULT. 1) Connect all connectors. 2) Change the SI-DRIVE mode.
The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause. Correct the cause Go to step 7. of trouble.
Replace the multiinformation display meter. <Ref. to IDI-22, Combination Meter.>
Replace the SIDRIVE selector or SI-DRIVE S# switch. <Ref. to FU(H6DO)-36, SIDRIVE (SUBARU Intelligent Drive) Selector.> or <Ref. to FU(H6DO)-37, SI-DRIVE (SUBARU Intelligent Drive) S# Switch.>
The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector may be the cause.
EN(H6DO)(diag)-350

2. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR APPEARS IN THE MULTI INFORMATION DISPLAY APPROXIMATELY 5 SECONDS LATER.
Step 1 CHECK DTC. Check Is DTC displayed? Yes No Check the correGo to step 2. sponding DTC using the List of Diagnostic Trouble Code (DTC) for each unit. For the diagnostic Go to step 3. procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
CHECK DISPLAY OF MULTI-INFORMATION DISPLAY METER. Check whether there are other errors displayed other than the Mode Change Error. Examples: Err is displayed in the external temperature or fuel consumption displays. FUEL gauge, TEMP gauge or ECO gauge does not move. CHECK MULTI-INFORMATION DISPLAY METER AND ECM.
Is there other errors displayed other than the Mode Change Error?
Is the multi-information display Replace the multimeter and ECM part numbers information discorrect? play meter. <Ref. to IDI-22, Combination Meter.>
Replace the multiinformation display meter or ECM to that of the correct part number. <Ref. to IDI-22, Combination Meter.> or <Ref. to FU(H6DO)-38, Engine Control Module (ECM).>
EN(H6DO)(diag)-351

3. WHEN THE SI-DRIVE MODE IS CHANGED, MODE CHANGE ERROR IS NOT DISPLAYED IN MULTI-INFORMATION DISPLAY, AND S#, I, S FLASHES.
NOTE: In this case, there may be a problem outside the SI-DRIVE system.
1 Step Check CHECK MALFUNCTION INDICATOR LIGHT. Does the malfunction indicator 1) Start the engine. light illuminate? 2) Check whether the malfunction indicator light is lit or not. Yes No Check the appro- Go to step 2. priate DTC using the List of Diagnostic Trouble Code (DTC). <Ref. to EN(H6DO)(diag)81, List of Diagnostic Trouble Code (DTC).> Investigate and Go to step 3. repair the cause of overheating.
Inspect and repair the cause of engine oil temperature rise. NOTE: Ask the customer whether the vehicle has experienced a long drive in low gear or towing of heavy load. If not, drive the vehicle again after the engine oil temperature lowers, and check if the oil temperature rises. CHECK DISPLAY OF MULTI-INFORMATION Do the displays S#, I, S of Replace the multiDISPLAY. the multi-information display information dis1) Turn the ignition switch to ON. flash? play meter. <Ref. 2) Change the SI-DRIVE mode. to IDI-22, Combi3) Check the display of the multi-information nation Meter.> display.
CHECK ENGINE COOLANT TEMPERATURE Is it overheating? GAUGE. 1) Turn the ignition switch to ON. 2) Check the engine coolant temperature gauge. CHECK ENGINE OIL TEMPERATURE. Is the engine oil temperature 1) Turn the ignition switch to ON. 117C (243F) or higher? 2) Check the engine oil temperature using Subaru Select Monitor. NOTE: For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-34, Subaru Select Monitor.>
Go to step 4.
Perform test operation, and check the malfunction indicator, the engine coolant temperature gauge and the engine oil temperature. If they are operating normally, end the diagnosis.
EN(H6DO)(diag)-352


A: INSPECTION
NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(H6DO)-85, Engine Trouble in General.>
Symptoms Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Ignition parts (*1) 1. Engine stalls during idling. 4) Engine coolant temperature sensor (*2) 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Ignition parts (*1) 5) Air intake system (*5) 2. Rough idling 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Crankshaft position sensor (*3) 9) Camshaft position sensor (*3) 10) Oxygen sensor 11) Fuel pump and fuel pump relay 1) Engine coolant temperature sensor 2) Electronic throttle control 3) Manifold absolute pressure sensor 3. Engine does not return to idle. 4) Mass air flow and intake air temperature sensor 5) Accelerator pedal position sensor 6) Oil temperature sensor 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Electronic throttle control 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay 6) Engine coolant temperature sensor (*2) 4. Poor acceleration 7) Crankshaft position sensor (*3) 8) Camshaft position sensor (*3) 9) A/C switch and A/C cut relay 10) Engine torque control signal circuit 11) Ignition parts (*1) 12) Accelerator pedal position sensor 13) Oil temperature sensor 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5. Engine stalls, engine sags or hesitates at acceleration. 5) Camshaft position sensor (*3) 6) Purge control solenoid valve 7) Fuel injection parts (*4) 8) Electronic throttle control 9) Fuel pump and fuel pump relay
EN(H6DO)(diag)-353

Symptoms Problem parts 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Fuel pump and fuel pump relay 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor 4) Knock sensor 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay
6. Surging
7. Spark knock
*1: Check ignition coil and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check the fuel injector and fuel pressure regulator. *5: Inspect air leak in air intake system.
EN(H6DO)(diag)-354

GENERAL DESCRIPTION

A: LIST
DTC P0011 Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank1) Crankshaft Position - Camshaft Position Correlation (Bank2) Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) Intake Valve Control Solenoid Circuit Range/Performance (Bank 1) Intake Valve Control Solenoid Circuit Range/Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) HO2S Heater Control Circuit (Bank 2 Sensor 1) HO2S Heater Control Circuit Low (Bank 2 Sensor 1) HO2S Heater Control Circuit High (Bank 2 Sensor 1) HO2S Heater Control Circuit Low (Bank 2 Sensor 2) HO2S Heater Control Circuit High (Bank 2 Sensor 2) MAP/MAF - Throttle Position Correlation Intake Valve Control Solenoid Circuit Low (Bank 1) Index <Ref. to GD(H6DO)-10, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-13, DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-13, DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-14, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-16, DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-17, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-19, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-21, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-23, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-25, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-26, DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-26, DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-26, DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-26, DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-26, DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-27, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-29, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0016
P0018
P0021
P0026
P0028
P0030 P0031
P0032
P0037
P0038
P0050 P0051
P0052
P0057
P0058
P0068 P0076
GD(H6DO)-2

GENERAL DESCRIPTION
DTC P0077 Item Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Intake Valve Control Solenoid Circuit High (Bank 2) Index <Ref. to GD(H6DO)-30, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-30, DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0082
P0083
P0101
P0102 P0103 P0107
P0108
P0111
P0112 P0113 P0117 P0118 P0122
P0123
P0125
P0126
P0128
P0131 P0132 P0133
<Ref. to GD(H6DO)-30, DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> Mass or Volume Air Flow Circuit <Ref. to GD(H6DO)-31, DTC P0101 MASS OR VOLUME AIR FLOW CIRRange/Performance CUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Mass or Volume Air Flow Circuit Low <Ref. to GD(H6DO)-33, DTC P0102 MASS OR VOLUME AIR FLOW CIRInput CUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Mass or Volume Air Flow Circuit High <Ref. to GD(H6DO)-34, DTC P0103 MASS OR VOLUME AIR FLOW CIRInput CUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Manifold Absolute Pressure/ <Ref. to GD(H6DO)-35, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/ Barometric Pressure Circuit Low Input BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Manifold Absolute Pressure/ <Ref. to GD(H6DO)-36, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/ Barometric Pressure Circuit High Input BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Intake Air Temperature Sensor 1 Circuit <Ref. to GD(H6DO)-37, DTC P0111 INTAKE AIR TEMPERATURE SENSOR Range/Performance 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Intake Air Temperature Sensor 1 Circuit <Ref. to GD(H6DO)-39, DTC P0112 INTAKE AIR TEMPERATURE SENSOR Low 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Intake Air Temperature Sensor 1 Circuit <Ref. to GD(H6DO)-40, DTC P0113 INTAKE AIR TEMPERATURE SENSOR High 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Engine Coolant Temperature Circuit <Ref. to GD(H6DO)-41, DTC P0117 ENGINE COOLANT TEMPERATURE Low CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Engine Coolant Temperature Circuit <Ref. to GD(H6DO)-42, DTC P0118 ENGINE COOLANT TEMPERATURE High CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H6DO)-43, DTC P0122 THROTTLE/PEDAL POSITION SENSwitch A Circuit Low SOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle/Pedal Position Sensor/ <Ref. to GD(H6DO)-44, DTC P0123 THROTTLE/PEDAL POSITION SENSwitch A Circuit High SOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> Insufficient Coolant Temperature for <Ref. to GD(H6DO)-45, DTC P0125 INSUFFICIENT COOLANT TEMPERAClosed Loop Fuel Control TURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.> Insufficient Engine Coolant Temperature <Ref. to GD(H6DO)-47, DTC P0126 INSUFFICIENT ENGINE COOLANT For Stable Operation TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> Coolant Thermostat <Ref. to GD(H6DO)-49, DTC P0128 COOLANT THERMOSTAT (ENGINE (Engine Coolant Temperature Below COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMThermostat Regulating Temperature) PERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.> O2 Sensor Circuit Low Voltage <Ref. to GD(H6DO)-51, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (Bank 1 Sensor 1) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> O2 Sensor Circuit High Voltage <Ref. to GD(H6DO)-53, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (Bank 1 Sensor 1) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> O2 Sensor Circuit Slow Response <Ref. to GD(H6DO)-55, DTC P0133 O2 SENSOR CIRCUIT SLOW (Bank 1 Sensor 1) RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-3

GENERAL DESCRIPTION
DTC P0134 Item O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank1 Sensor2) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1) O2 Sensor Circuit High Voltage (Bank 2 Sensor 1) O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2) O2 Sensor Circuit High Voltage (Bank 2 Sensor 2) O2 Sensor Circuit Slow Response (Bank 2 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank2 Sensor2) System Too Lean (Bank 1) System Too Rich (Bank 1) System Too Lean (Bank 2) System Too Rich (Bank 2) Fuel Temperature Sensor A Circuit Range/Performance Fuel Temperature Sensor A Circuit Low Input Fuel Temperature Sensor A Circuit High Input Engine Oil Temperature Sensor Circuit Range/Performance Engine Oil Temperature Sensor Low Engine Oil Temperature Sensor High Index <Ref. to GD(H6DO)-58, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-60, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-63, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-64, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-69, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-71, DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-72, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-73, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-74, DTC P0174 SYSTEM TOO LEAN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-74, DTC P0175 SYSTEM TOO RICH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-75, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-78, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-79, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-80, DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-82, DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-83, DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0137 P0138 P0139
P0140
P0151 P0152 P0153
P0154
P0157 P0158 P0159
P0160
P0171 P0172 P0174 P0175 P0181
P0182 P0183 P0196
P0197 P0198
GD(H6DO)-4

GENERAL DESCRIPTION
DTC P0222 Item Throttle/Pedal Position Sensor/ Switch B Circuit Low Throttle/Pedal Position Sensor/ Switch B Circuit High Fuel Pump Primary Circuit Cylinder 1 Misfire Detected Cylinder 2 Misfire Detected Cylinder 3 Misfire Detected Cylinder 4 Misfire Detected Cylinder 5 Misfire Detected Cylinder 6 Misfire Detected Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) Knock Sensor 2 Circuit Low (Bank 2) Knock Sensor 2 Circuit High (Bank 2) Crankshaft Position Sensor A Circuit Crankshaft Position Sensor A Circuit Range/Performance Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor) Camshaft Position Sensor A Circuit (Bank 2) Exhaust Gas Recirculation Flow Catalyst System Efficiency below Threshold (Bank 1) Evaporative Emission Control System Leak Detected (Small Leak) Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Index <Ref. to GD(H6DO)-84, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-85, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-86, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-88, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-93, DTC P0302 CYLINDER 2 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-93, DTC P0303 CYLINDER 3 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-93, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-93, DTC P0305 CYLINDER 5 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-93, DTC P0306 CYLINDER 6 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-94, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-95, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-96, DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-96, DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-97, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-99, DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-101, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-102, DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-103, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-106, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-108, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-124, DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-126, DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0223
P0230 P0301 P0302 P0303 P0304 P0305 P0306 P0327
P0328
P0332 P0333 P0335 P0336
P0340
P0345 P0400 P0420
P0442
P0447
P0448
GD(H6DO)-5

GENERAL DESCRIPTION
DTC P0451 Item Evaporative Emission Control System Pressure Sensor Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission Control System Leak Detected (Very Small Leak) Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Evaporative Emission System Purge Control Valve Circuit Low Evaporative Emission System Purge Control Valve Circuit High Fuel Level Sensor A Circuit Range/ Performance Fuel Level Sensor A Circuit Low Fuel Level Sensor A Circuit High Fuel Level Sensor Circuit Intermittent Vehicle Speed Sensor A Idle Air Control System RPM Lower Than Expected Index <Ref. to GD(H6DO)-128, DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-130, DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-132, DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-133, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-133, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-134, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-136, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-138, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-140, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-142, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-144, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-147, DTC P0500 VEHICLE SPEED SENSOR A, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0452
P0453
P0456
P0457
P0458
P0459
P0461
P0462 P0463 P0464 P0500 P0506
P0507
P0512 P0513 P0600 P0604
P0605
P0607
P0638
<Ref. to GD(H6DO)-148, DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Idle Air Control System RPM Higher <Ref. to GD(H6DO)-149, DTC P0507 IDLE AIR CONTROL SYSTEM RPM Than Expected HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.> Starter Request Circuit <Ref. to GD(H6DO)-150, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.> Incorrect Immobilizer Key <Ref. to GD(H6DO)-151, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.> Serial Communication Link <Ref. to GD(H6DO)-152, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Trouble Code (DTC) Detecting Criteria.> Internal Control Module Random <Ref. to GD(H6DO)-154, DTC P0604 INTERNAL CONTROL MODULE Access Memory (RAM) Error RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> Internal Control Module Read Only <Ref. to GD(H6DO)-155, DTC P0605 INTERNAL CONTROL MODULE Memory (ROM) Error READ ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Control System Circuit Range/ <Ref. to GD(H6DO)-156, DTC P0607 THROTTLE CONTROL SYSTEM CIRPerformance CUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> Throttle Actuator Control Range/ <Ref. to GD(H6DO)-159, DTC P0638 THROTTLE ACTUATOR CONTROL Performance (Bank 1) RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-6

GENERAL DESCRIPTION
DTC P0700 P1152 Item Transmission Control System (MIL Request) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (Low) (Bank 2 Sensor 1) O2 Sensor Circuit Range/Performance (High) (Bank 2 Sensor 1) Return Spring Failure Fuel Tank Pressure Control Solenoid Valve Circuit Low Fuel Tank Pressure Control Sol. Valve Circuit High Vent Control Solenoid Valve Function Problem EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input) Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure (Except Antenna Circuit) Index <Ref. to GD(H6DO)-161, DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-162, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-164, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-166, DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-166, DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-167, DTC P1160 RETURN SPRING FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-169, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-171, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-173, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-175, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-177, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-179, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-180, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-181, DTC P1570 ANTENNA, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-181, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-181, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1153
P1154
P1155
P1160 P1400
P1420
P1443 P1492
P1493
P1494
P1495
P1496
P1497
P1498
P1499
P1560 P1570 P1571 P1572
GD(H6DO)-7

GENERAL DESCRIPTION
DTC P1574 P1576 P1577 P1578 P1602 P2088 Item Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Control Module Programming Error Intake Camshaft Position Actuator Control Circuit Low (Bank 1) Intake Camshaft Position Actuator Control Circuit High (Bank 1) Intake Camshaft Position Actuator Control Circuit Low (Bank 2) Intake Camshaft Position Actuator Control Circuit High (Bank 2) Post Catalyst Fuel Trim System Too Lean (Bank 1) Post Catalyst Fuel Trim System Too Rich (Bank 1) Post Catalyst Fuel Trim System Too Lean Bank 2 Post Catalyst Fuel Trim System Too Rich Bank 2 Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle/Pedal Position Sensor A Minimum Stop Performance Throttle/Pedal Position Sensor/Switch D Circuit Low Input Throttle/Pedal Position Sensor/Switch D Circuit High Input Throttle/Pedal Position Sensor/Switch E Circuit Low Input Index <Ref. to GD(H6DO)-181, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-181, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-181, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-181, DTC P1578 METER FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-182, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-184, DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-185, DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-186, DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-186, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-187, DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-189, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-190, DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-190, DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-191, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-193, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-195, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-197, DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-199, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-201, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-203, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2089
P2092
P2093
P2096
P2097
P2098
P2099
P2101
P2102 P2103
P2109
P2122
P2123
P2127
GD(H6DO)-8

GENERAL DESCRIPTION
DTC P2128 Item Throttle/Pedal Position Sensor/ Switch E Circuit High Input Throttle/Pedal Position Sensor/ Switch A/B Voltage Correlation Throttle/Pedal Position Sensor/ Switch D/E Voltage Correlation Barometric Pressure Circuit Range/ Performance Barometric Pressure Circuit Low Barometric Pressure Circuit High Index <Ref. to GD(H6DO)-205, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-207, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-209, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-211, DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-212, DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H6DO)-213, DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2135
P2138
P2227
P2228 P2229
GD(H6DO)-9

GENERAL DESCRIPTION

Detect the AVCS system malfunction. Judge NG when the amount of AVCS actual timing advance does not approach to the amount of AVCS target timing advance.
(3) (1) (5) (2)
(4)
EN-01852
(1) (2)
(3) (4)
(5)
Oil pressure
3. ENABLE CONDITION
Secondary Parameters Time of establishing all secondary parameter conditions Battery voltage Engine speed Engine coolant temperature AVCS control Target advance angle Target timing advance change amount (per 64 ms) Enable Conditions t 3000 ms t 10.9 V t 1500 rpm t 50 C (122 F) Operation t 0 CA < 1.07 CA

Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates.
GD(H6DO)-10

GENERAL DESCRIPTION
1) When the conditions during which the differences of AVCS target timing advance amount and AVCS actual timing advance amount is large continues for certain amount of time. 2) When the differences of target timing advance amount and actual timing advance amount is calculated during AVCS control, and the difference per predetermined time is the specified value or larger. Abnormality Judgement Judge as NG when the following conditions are established within the predetermined time. Judgement Value
Malfunction criteria 6(Target position Actual position) or 6(Target position Actual position) Threshold value > 8000 CA (Bank 1) > 8000 CA (Bank 2) < 2500 CA (Bank 1) < 2500 CA (Bank 2)
Time Needed for Diagnosis: 30000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the following conditions are established within the predetermined time. Judgement Value
Malfunction criteria 6(Target position Actual position) Threshold value d 8000 CA (Bank 1) d 8000 CA (Bank 2) and t 2500 CA (Bank 1) t 2500 CA (Bank 2)
GD(H6DO)-11

GENERAL DESCRIPTION

Detect the AVCS system malfunction. Judge as NG when the timing advance is outside the normal range.
(3) (1) (5) (2)
(4)
EN-01852
(1) (2)
(3) (4)
(5)
Oil pressure
3. ENABLE CONDITION
Secondary Parameters Battery voltage Engine speed Engine coolant temperature AVCS control Target timing advance Enable Conditions t 10.9 V t 500 rpm t 50 C (122 F) Not in operation 0CA

Perform the diagnosis continuously after starting engine and while AVCS is not operating.
GD(H6DO)-12

GENERAL DESCRIPTION
Judge as NG when the camshaft sensor input position is not within the normal range. Abnormality Judgement If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Crankshaft position when camshaft position sensor signal is input Threshold Value < BTDC 22 CA (Bank 1) < BTDC 22 CA (Bank 2) or > BTDC 58 CA (Bank 1) > BTDC 58 CA (Bank 2)
Malfunction Criteria Crankshaft position when camshaft position sensor signal is input Threshold Value t BTDC 22 CA (Bank 1) t BTDC 22 CA (Bank 2) and d BTDC 58 CA (Bank 1) d BTDC 58 CA (Bank 2)

NOTE: For the detection standard, refer to DTC P0016. <Ref. to GD(H6DO)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
NOTE: For the detection standard, refer to DTC P0011. <Ref. to GD(H6DO)-10, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-13

GENERAL DESCRIPTION
E: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 1)
Judge as NG with either Low NG or High NG. A variable valve lift diagnosis oil pressure switch is installed for diagnosis. It is possible to determine whether the intake valve is in high mode (increase the amount of lift) or in low mode (suppressing the amount of lift) when the variable valve lift diagnosis oil pressure switch is turned ON or OFF. Normal
Oil switching solenoid valve duty Large Minimum Intake valve High mode Low mode Variable valve lift diagnosis oil pressure switch ON OFF
Low NG When the variable valve lift diagnosis oil pressure switch remains OFF even though the intake valve tried to enter high mode (oil switching solenoid valve duty is large), this is judged as a Low NG. High NG When the variable valve lift diagnosis oil pressure switch remains ON even though the intake valve tried to enter low mode (oil switching solenoid valve duty is small), this is judged as a High NG.
GD(H6DO)-14

GENERAL DESCRIPTION
The variable valve lift system optimizes the intake valve lift by switching between the low lift cam and the high lift cam according to the engine speed. The amount of intake valve lift is varied by controlling the oil switching solenoid valve duty according to signals from the ECM.
(1)
(A)
(B)
EN-03119
(A) (1)
When at low speed Oil switching solenoid valve
(B)
When at high speed
3. ENABLE CONDITION
Secondary Parameters Battery voltage After engine starting Engine oil temperature Variable valve lift control Enable Conditions t 10.9 V t 6000 ms t 0 C (32 F) Operation
GD(H6DO)-15

GENERAL DESCRIPTION

Perform the diagnosis continuously 6 seconds after engine start while variable valve lift is being controlled
Malfunction Criteria Low Duty ratio Variable valve lift diagnosis oil pressure switch High Duty ratio Variable valve lift diagnosis oil pressure switch Threshold Value t 62 % OFF
< 33 % ON
Time Needed for Diagnosis: Low side: 784 ms High side: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction criteria Low Duty ratio Variable valve lift diagnosis oil pressure switch High Duty ratio Variable valve lift diagnosis oil pressure switch Threshold value t 62 % ON
< 33 % OFF
Time Needed for Diagnosis: Low side: 208 ms High side: 3000 ms
F: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/ PERFORMANCE (BANK 2)
NOTE: For the detection standard, refer to DTC P0026. <Ref. to GD(H6DO)-14, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-16

GENERAL DESCRIPTION
G: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

(1)
(2)
(4)
(3)
EN-02181
(1) (2)
(3)
Sensor housing
(4)
Protection tube
3. ENABLE CONDITION

GD(H6DO)-17

GENERAL DESCRIPTION
Malfunction criteria Front oxygen (A/F) sensor impedance Threshold value > 50 :
Malfunction criteria Front oxygen (A/F) sensor impedance Threshold value d 50 :
GD(H6DO)-18

GENERAL DESCRIPTION

(A) OFF (B)
ON 0V
(D)
(C)
EN-01792
(A) (B)
(C)
128 milliseconds
(D)
Low error
3. ENABLE CONDITION

GD(H6DO)-19

GENERAL DESCRIPTION
GD(H6DO)-20

GENERAL DESCRIPTION
I:
(A) (D) (B) OFF
ON 0V
(C)
EN-01793
(A) (B)
(C)
128 milliseconds
(D)
High error
3. ENABLE CONDITION

GD(H6DO)-21

GENERAL DESCRIPTION
GD(H6DO)-22

GENERAL DESCRIPTION
J: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

(A) OFF (B)
ON 0V
(D)
(C)
EN-01792
(A) (B)
(C)
(D)
Low error
3. ENABLE CONDITION

GD(H6DO)-23

GENERAL DESCRIPTION
GD(H6DO)-24

GENERAL DESCRIPTION
K: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

(A) (D) (B) OFF
ON 0V
(C)
EN-01793
(A) (B)
(C)
(D)
High error
3. ENABLE CONDITION

GD(H6DO)-25

GENERAL DESCRIPTION
L: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P0030. <Ref. to GD(H6DO)-17, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
M: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P0031. <Ref. to GD(H6DO)-19, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
N: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P0032. <Ref. to GD(H6DO)-21, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
O: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2)

NOTE: For the detection standard, refer to DTC P0037. <Ref. to GD(H6DO)-23, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2)

NOTE: For the detection standard, refer to DTC P0038. <Ref. to GD(H6DO)-25, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-26

GENERAL DESCRIPTION
Q: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H6DO)-27

GENERAL DESCRIPTION
Malfunction criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load Threshold value < 2500 rpm t 15 < 2.12 V > 0.87 g/rev (0.03 oz/rev) 500 rpm 850 rpm < 3.5 t 2.66 V < 0.6 g/rev (0.02 oz/rev)
Malfunction criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load Threshold value < 2500 rpm t 15 t 2.12 V > 0.87 g/rev (0.03 oz/rev) 500 rpm 850 rpm < 3.5 < 2.66 V < 0.6 g/rev (0.02 oz/rev)
GD(H6DO)-28

GENERAL DESCRIPTION
R: DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)

Detect the open circuit of the oil switching solenoid valve. Judge as NG when the current is small even though the output duty is large.
2. ENABLE CONDITION

Malfunction criteria Duty ratio Control current Threshold value t 30 % < 0.026 A
Malfunction Criteria |Oil switching solenoid valve target current value Oil switching solenoid valve current value| Target current Threshold Value < 0.08 A
t 0.11 A
GD(H6DO)-29

GENERAL DESCRIPTION
S: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)

Detect short circuits of the oil switching solenoid valve. Judge as a short NG when the current is large even though the output duty is small.
2. ENABLE CONDITION

Malfunction criteria Duty ratio Control current Threshold value <7% t 0.465 A
Malfunction Criteria |Oil switching solenoid valve target current value Oil switching solenoid valve current value| Threshold Value < 0.08 A
T: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)

NOTE: For the detection standard, refer to DTC P0076. <Ref. to GD(H6DO)-29, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
U: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)

NOTE: For the detection standard, refer to DTC P0077. <Ref. to GD(H6DO)-30, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-30

GENERAL DESCRIPTION
V: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION

GD(H6DO)-31

GENERAL DESCRIPTION
Malfunction criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High (1) Output voltage Engine speed Throttle opening angle Intake manifold pressure High (2) Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis Threshold value < 1.79 V t 2000 rpm t 15 t 73.3 kPa (550 mmHg, 21.7 inHg) t 1.83 V 500 rpm 850 rpm < 3.5 t 46.7 kPa (350 mmHg, 13.8 inHg) t 1.73 V 500 rpm 850 rpm < 3.5 t 46.7 kPa (350 mmHg, 13.8 inHg) Rich side malfunction
Malfunction criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis Threshold value t 1.79 V t 2000 rpm t 15 t 73.3 kPa (550 mmHg, 21.7 inHg) < 1.83 V 500 rpm 850 rpm < 3.5 < 46.7 kPa (350 mmHg, 13.8 inHg) Rich side normal
GD(H6DO)-32

GENERAL DESCRIPTION
W: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION

Malfunction criteria Output voltage Threshold value d 0.200 V
Malfunction criteria Output voltage Threshold value > 0.200 V
GD(H6DO)-33

GENERAL DESCRIPTION
X: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

(1)
(3)
(2) (A)
(4)
EN-01766
(A) (1) (2)
3. ENABLE CONDITION

Malfunction criteria Output voltage Threshold value t 4.791 V
Malfunction criteria Output voltage Threshold value < 4.791 V
GD(H6DO)-34

GENERAL DESCRIPTION
Y: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT

(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

Malfunction criteria Output voltage Threshold value d 0.568 V
Malfunction criteria Output voltage Threshold value > 0.568 V
GD(H6DO)-35

GENERAL DESCRIPTION
Z: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT

(1)
(2)
(A)
(3)
(B)
EN-01765
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H6DO)-36

GENERAL DESCRIPTION
AA:DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/ PERFORMANCE

(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION
Secondary Parameters Engine coolant temperature at engine starting Engine coolant temperature Battery voltage Continuous time when the vehicle speed is less than 60 km/h (37.3 MPH Enable Conditions < 30 C (86 F) t 95 C (203 F) t 10.9 V t 600 s

GD(H6DO)-37

GENERAL DESCRIPTION
Malfunction criteria Output voltage difference between Max. and Min. Threshold value < 0.02 V(Equivalent to approximately 0.5C (0.9F) near 25C)
Malfunction criteria Output voltage difference between Max. and Min. Threshold value t 0.02 V
GD(H6DO)-38

GENERAL DESCRIPTION
AB:DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION

GD(H6DO)-39

GENERAL DESCRIPTION
AC:DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

(1)
(3)
(2) (A) (4)
EN-01767
(A) (1) (2)
3. ENABLE CONDITION

GD(H6DO)-40

GENERAL DESCRIPTION
AD:DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H6DO)-41

GENERAL DESCRIPTION
AE:DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H6DO)-42

GENERAL DESCRIPTION
AF:DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

Malfunction criteria Sensor 1 input voltage Threshold value d 0.224 V
Malfunction criteria Sensor 1 input voltage Threshold value > 0.224 V
GD(H6DO)-43

GENERAL DESCRIPTION
AG:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

Malfunction criteria Sensor 1 input voltage Threshold value t 4.851 V
Malfunction criteria Sensor 1 input voltage Threshold value < 4.851 V
GD(H6DO)-44

GENERAL DESCRIPTION
AH:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION
Secondary Parameters Engine speed Battery voltage Enable Conditions t Value from Map t 10.9 V
Map
Engine coolant temperature C (F) Engine speed rpm 40 (40) 500 110 (230) 500

GD(H6DO)-45

GENERAL DESCRIPTION
0 (0) 20 (4) 10 (14) Temperature 0 (32) C (F) 10 (50) 20 (68) 0 ms 0 ms 0 ms 0 ms 0 ms 8 (5) 37.136 ms 27.391 ms 17.646 ms 7.9012 ms 7.9012 ms 16 (9.9) 74.272 ms 54.782 ms 35.292 ms 15.802 ms 15.802 ms Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 40 (24.9) 111.41 ms 82.173 ms 52.938 ms 23.704 ms 23.704 ms 126.66 ms 99.65 ms 72.64 ms 45.63 ms 45.63 ms 141.91 ms 117.13 ms 92.341 ms 67.556 ms 67.556 ms 48 (29.8) 163.59 ms 135.96 ms 108.34 ms 80.711 ms 80.711 ms 56 (34.8) 185.26 ms 154.8 ms 124.33 ms 93.867 ms 93.867 ms
GD(H6DO)-46

GENERAL DESCRIPTION
AI: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
(1)
(A)
(B)
(2) EN-02917
(A) (1)
(B) (2)
3. ENABLE CONDITION

GD(H6DO)-47

GENERAL DESCRIPTION
t 5 C (41 F) < 2.5 C (36.5 F) < 35 C (95 F)
GD(H6DO)-48

GENERAL DESCRIPTION
AJ:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
(8)
(2)
(2)
(7)
(6)
(5)
(9)
(4) (3)
(1)
EN-01692
(1) (2) (3)
(4) (5) (6)
(7) (8) (9)
3. ENABLE CONDITION

GD(H6DO)-49

GENERAL DESCRIPTION
Time Needed for Diagnosis: 64 ms 3 time(s) 120 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
GD(H6DO)-50

GENERAL DESCRIPTION
AK:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H6DO)-51

GENERAL DESCRIPTION
Malfunction criteria Input voltage or Input current Threshold value < 1.800 V < 0.005 A
Malfunction criteria Input voltage Input current Threshold value t 1.800 V t 0.005 A
GD(H6DO)-52

GENERAL DESCRIPTION
AL:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H6DO)-53

GENERAL DESCRIPTION
Malfunction criteria Input voltage or Input current Threshold value > 3.800 V > 0.005 A
Malfunction criteria Input voltage Input current Threshold value d 3.800 V d 0.005 A
GD(H6DO)-54

GENERAL DESCRIPTION
AM:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

(2) (1)
(3)
EN-01694
(1)
Cover
(2)
Zirconia
(3)
Clogging
GD(H6DO)-55

GENERAL DESCRIPTION
(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H6DO)-56

GENERAL DESCRIPTION
Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n1) + |d2faf (n)| td2lmd (N) = td2lmd (n1) + |d2lmd (n)| add up to 32 ms 4 820 time(s). d2faf (n) = (faf (n) faf (n1)) (faf (n1) faf (n2)) d2lmd (n) = (lmd (n) lmd (n1)) (lmd (n1) lmd (n2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds Threshold Value > 0.2
Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n1) + |d2faf (n)| td2lmd (N) = td2lmd (n1) + |d2lmd (n)| add up to 32 ms 4 820 time(s). d2faf (n) = (faf (n) faf (n1)) (faf (n1) faf (n2)) d2lmd (n) = (lmd (n) lmd (n1)) (lmd (n1) lmd (n2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds Threshold Value d 0.2
GD(H6DO)-57

GENERAL DESCRIPTION
AN:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
3. ENABLE CONDITION

GD(H6DO)-58

GENERAL DESCRIPTION
GD(H6DO)-59

GENERAL DESCRIPTION
AO:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
GD(H6DO)-60

GENERAL DESCRIPTION
3. ENABLE CONDITION

GD(H6DO)-61

GENERAL DESCRIPTION

Malfunction Criteria High Sensor output voltage Low Sensor output voltage Threshold Value > 1.200 V < 0.030 V P0138 P0158 P0137 P0157 DTC
Fuel Cut Time (second) Time needed for diagnosis (second) 0 40000 2000 40000 10000 60000
Malfunction Criteria High Sensor output voltage Low Sensor output voltage Threshold Value d 1.200 V t 0.030 V P0138 P0158 P0137 P0157 DTC
GD(H6DO)-62

GENERAL DESCRIPTION
AP:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

NOTE: For the detection standard, refer to DTC P0137. <Ref. to GD(H6DO)-60, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-63

GENERAL DESCRIPTION
AQ:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

Detect the slow response of the oxygen sensor. Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and Judge as OK if both are OK. [Rich o lean diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean. If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK. 2. Judge as NG when the oxygen sensor voltage is large (rich) when recovering from a deceleration fuel cut. [Lean o rich diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich. If the measured response time is larger than the threshold value, it is NG. 2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel cut. Diagnostic method Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to lean. And Judge as NG when the measured response time is larger than the threshold value.
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION
GD(H6DO)-64

GENERAL DESCRIPTION

(A) (B)
EN-05566
(A) (B) (C) (D)
0.55 V 0.5 V 0.2 V 0.15 V
(E) (F) (G)
(H)
GD(H6DO)-65

GENERAL DESCRIPTION
Malfunction criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V or Longest time over 0.55 V Threshold value > 491 ms
t 2000 ms
Judgement Value
Malfunction criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V Threshold value d 491 ms
6. ENABLE CONDITION
Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time is 5000 ms or more. After fuel cut Current calculation time of the rear oxygen sensor heater Current continuation time of the rear oxygen sensor heater Estimated catalyst temperature Number of deceleration fuel cut Enable Conditions t 10.9 V Completed Experienced t 2000 ms t 0 ms t 0 ms t 0 C (32 F) t 1 time(s)
GD(H6DO)-66

GENERAL DESCRIPTION

(H)
(A) (B)
(C) (D) (E)
(J)
EN-05567
(A) (B) (C) (D) (E) (F)
(G) (H) (I)
(J)
GD(H6DO)-67

GENERAL DESCRIPTION
t 120000 ms
Judgement Value
Malfunction criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V Threshold value d 2000 ms
GD(H6DO)-68

GENERAL DESCRIPTION
AR:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)

(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)


GD(H6DO)-69

GENERAL DESCRIPTION
GD(H6DO)-70

GENERAL DESCRIPTION
AS:DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)

AT:DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P0132. <Ref. to GD(H6DO)-53, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
AU:DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P0133. <Ref. to GD(H6DO)-55, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
AV:DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P0134. <Ref. to GD(H6DO)-58, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
AW:DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2)

AX:DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2)

AY:DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2)

NOTE: For the detection standard, refer to DTC P0139. <Ref. to GD(H6DO)-64, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
AZ:DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2)

NOTE: For the detection standard, refer to DTC P0140. <Ref. to GD(H6DO)-69, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-71

GENERAL DESCRIPTION
BA:DTC P0171 SYSTEM TOO LEAN (BANK 1)

2. ENABLE CONDITION
Map1

Malfunction criteria fsobd = (sglmd tglmda) + faf + flaf In this case: sglmd = measured lambda tglmda = target lambda faf = main feedback compensation coefficient every 64 milliseconds flaf = main feedback learning compensation coefficient Threshold value t Value of Map 2
Map2
GD(H6DO)-72

GENERAL DESCRIPTION
BB:DTC P0172 SYSTEM TOO RICH (BANK 1)

2. ENABLE CONDITION
Map1

Malfunction criteria Threshold value fsobd = (sglmd tglmda) + faf + flaf < Value of Map 2 In this case: sglmd = measured lambda tglmda = target lambda faf = main feedback compensation coefficient every 64 milliseconds flaf = main feedback learning compensation coefficient
Map2
GD(H6DO)-73

GENERAL DESCRIPTION
BC:DTC P0174 SYSTEM TOO LEAN (BANK 2)

NOTE: For the detection standard, refer to DTC P0171. <Ref. to GD(H6DO)-72, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
BD:DTC P0175 SYSTEM TOO RICH (BANK 2)

NOTE: For the detection standard, refer to DTC P0172. <Ref. to GD(H6DO)-73, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-74

GENERAL DESCRIPTION
BE:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/ PERFORMANCE

(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION
DRIFT DIAGNOSIS

GD(H6DO)-75

GENERAL DESCRIPTION
Malfunction criteria Fuel level Elapsed time after starting the engine Engine coolant temperature Engine coolant temperature at engine start Fuel temperature Engine coolant temperature Battery voltage Threshold value t 9.6 2 (2.54 US gal, 2.11 Imp gal) t 20 s > 10 C (50 F) t 10 C (50 F) t 10.9 V
Malfunction criteria Fuel level Elapsed time after starting the engine Engine coolant temperature Engine coolant temperature at engine start Fuel temperature Engine coolant temperature Battery voltage Engine coolant temperature Threshold value t 9.6 2 (2.54 US gal, 2.11 Imp gal) t 20 s > 10 C (50 F) < 10 C (50 F) t 10.9 V < 75 C (167 F)
6. ENABLE CONDITION
Stuck Diagnosis

GD(H6DO)-76

GENERAL DESCRIPTION
Malfunction criteria Accumulated amount of intake air Fuel temperature difference between Max. and Min. Threshold value t 551043 g (19435.29 oz) < 2 C (35.6 F)
Malfunction criteria Fuel temperature difference between Max. and Min. Threshold value t 2 C (35.6 F)
GD(H6DO)-77

GENERAL DESCRIPTION
BF:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION

Malfunction criteria Output voltage Battery voltage Threshold value < 0.344 V t 10.9 V
Malfunction criteria Output voltage Battery voltage Threshold value t 0.344 V t 10.9 V
GD(H6DO)-78

GENERAL DESCRIPTION
BG:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

(A)
(B)
EN-01700
(A)
(B)
3. ENABLE CONDITION

Malfunction criteria Output voltage Battery voltage Threshold value t 4.716 V t 10.9 V
Malfunction criteria Output voltage Battery voltage Threshold value < 4.716 V t 10.9 V
GD(H6DO)-79

GENERAL DESCRIPTION
BH:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE

Detect for abnormal values in the oil temperature sensor output properties. Judge as NG when the oil temperature does not rise even though the engine is running under a condition where it should rise.
2. ENABLE CONDITION
Secondary Parameters Battery voltage Engine speed Enable Conditions t 10.9 V t Value from Map
Map
Engine coolant temperature C (F) Engine speed rpm 40 (40) 500 110 (230) 500

GD(H6DO)-80

GENERAL DESCRIPTION
Malfunction Criteria Engine oil temperature After engine start oil temperature sensor characteristic diagnosis timer. Threshold Value < 15 C (59 F) t Judgement value for after engine start oil temperature sensor characteristic diagnosis timer
After engine start oil temperature sensor characteristic diagnosis timer (timer for diagnosis). a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 milliseconds + TOILCNT milliseconds (at the time of 64 milliseconds). Where, TOILCNT is determined as follows, TOILCNT = 0 at idle switch ON For TOILCNT at Idle switch off, refer to the following table.
0 (0) 0 ms 67 ms 98 ms 145 ms 161 ms 8 (5) 32 ms 93 ms 123 ms 166 ms 187 ms 16 (9.9) 76 ms 121 ms 148 ms 187 ms 212 ms Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 40 (24.9) 130 ms 149 ms 171 ms 157 ms 170 ms 184 ms 184 ms 193 ms 204 ms 208 ms 223 ms 239 ms 243 ms 252 ms 262 ms 48 (29.8) 176 ms 193 ms 214 ms 242 ms 266 ms 56 (34.8) 181 ms 203 ms 226 ms 245 ms 270 ms
40 (40) 30 (22) Temperature 20 (4) C (F) 10 (14) 0 (32)
After engine start oil temperature characteristic diagnosis timer judgment value (t). t = 2400000 ms 60000 ms Ti (t t 2400000) Ti = The lowest coolant temperature after starting the engine. Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria Engine oil temperature Threshold Value t 15 C (59 F)
GD(H6DO)-81

GENERAL DESCRIPTION
BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW

2. ENABLE CONDITION

GD(H6DO)-82

GENERAL DESCRIPTION
BJ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH

2. ENABLE CONDITION

GD(H6DO)-83

GENERAL DESCRIPTION
BK:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

Malfunction criteria Sensor 2 input voltage Threshold value d 0.926 V
Malfunction criteria Sensor 2 input voltage Threshold value > 0.926 V
GD(H6DO)-84

GENERAL DESCRIPTION
BL:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H6DO)-85

GENERAL DESCRIPTION
BM:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

Detect the malfunction of fuel pump control unit. Judge as NG when the NG signal is sent through a diagnostic line coming from the fuel pump control unit. Fuel pump control unit detects the open or short circuit malfunction for each line, and then sends NG signals if one of them is found NG.
+B FPC (1) DI (2) FPFP+ (3) (4)
E
EN-01771
(1) (2)
Engine control module (ECM) Fuel pump control unit
(3)
Fuel pump
(4)
Battery
3. ENABLE CONDITION

GD(H6DO)-86

GENERAL DESCRIPTION
Malfunction criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level Threshold value t8V t 180000 ms ON Low t 9.6 2 (2.54 US gal, 2.11 Imp gal)
Malfunction criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level Threshold value t8V t 180000 ms ON High t 9.6 2 (2.54 US gal, 2.11 Imp gal)
GD(H6DO)-87

GENERAL DESCRIPTION
BN:DTC P0301 CYLINDER 1 MISFIRE DETECTED

Detect the presence of misfire occurrence. (Revolution fluctuation method) Monitoring Misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made obligatory by the law. Misfire affecting these two has two patterns below. : Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.): FTP 1.5 times misfire Every time misfire (The same cylinder misfires every time.): FTP 1.5 times misfire, Catalyst damage misfire The following detecting methods are adopted for these detection. 1) Intermittent misfire: FTP 1.5 times misfire 120 Interval Difference Method 360 Interval Difference Method (whole range) 720 Interval Difference Method (3,000 rpm or more) 2) Misfire every time: FTP 1.5 times misfire, Catalyst damage misfire 360 Interval Difference Method
2. ENABLE CONDITION
Secondary Parameters All secondary parameters enable conditions Intake manifold pressure change at 120CA Throttle position change during 16 milliseconds Fuel shut-off function Fuel level Vehicle dynamic control or AT torque control Evaporative system leak check Engine speed Intake manifold pressure Battery voltage Fuel parameter determination Enable Conditions t 1024 ms < Value of Map 1 < 20 Not in operation t 9.6 2 (2.54 US gal, 2.11 Imp gal) Not in operation
Not in operation 400 rpm 8000 rpm t Value of Map 2 t8V Not extremely low volatility Elapsed time after starting the engine t 0 ms Engine speed change during 32 millisec- < 500 rpm onds
Map1
rpm kPa (mmHg, inHg) 700 20 (150, 5.9) 1000 20 (150, 5.9) 1500 20 (150, 5.9) 2000 20 (150, 5.9) 2500 20 (150, 5.9) 3000 20 (150, 5.9) 3500 20 (150, 5.9) 4000 20 (150, 5.9) 4500 20 (150, 5.9) 5000 20 (150, 5.9) 5500 20 (150, 5.9) 6000 20 (150, 5.9) 6500 20 (150, 5.9) 7000 20 (150, 5.9)
Map2
rpm kPa (mmHg, inHg) 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 28.3 32.3 36.3 36.3 37.2 38.1 41.9 48.9 26.7 23.3 23.3 23.3 23.6 24.4 (200.0, (175.0, (175.0, (175.0, (177.0, (183.0, (212.5, (242.2, (272.0, (272.0, (279.0, (286.0, (314.0, (367.0, 7.2) 8.4) 9.5) 10.7) 10.7) 11) 11.3) 12.4) 14.4) 7.9) 6.9) 6.9) 6.9) 7)
GD(H6DO)-88

GENERAL DESCRIPTION

(A)
#1
#6
#3
#2
#5
#4
#1
#6
#3
#2
(B)
omg7
omg6
omg5
omg4
omg3
omg2
omg1
omg0
EN-02184
(A)
Ignition order
(B)
GD(H6DO)-89

GENERAL DESCRIPTION

domg120 Threshold value (positive number)
domg120
Threshold value (negative number)
Judged as misfire
EN-02185

domg360 Threshold value
domg360
Judged as misfire
EN-02279
GD(H6DO)-90

GENERAL DESCRIPTION

domg720
Threshold value
domg720
Judged as misfire
EN-02280
Malfunction Criteria FTP emission judgment value Threshold Value t 27 100/3000% in 1000 revs.
Malfunction criteria FTP emission judgment value Threshold value < 27 100/3000% in 1000 revs.
GD(H6DO)-91

GENERAL DESCRIPTION
Malfunction criteria Catalyst damage misfire judgment value Threshold value t Value of Map 3
Map 3
0.2 (0.01) 700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 90 90 89 88 88 64 50 40 50 40 40 36 32 32 0.4 (0.01) 90 90 88 84 80 56 40 38 30 30 30 36 32 32 0.6 (0.02) 88 88 80 64 56 30 30 30 30 30 30 30 30 30 0.8 (0.03) 76 76 64 40 36 30 30 30 30 30 30 30 30 30 Intake air (g(oz)/rev) 1 1.2 (0.04) (0.04) 68 68 56 36 30 30 30 30 30 30 30 30 30 30 68 68 56 35 30 30 30 30 30 30 30 30 30 30 1.4 (0.05) 68 68 56 35 30 30 30 30 30 30 30 30 30 30 1.6 (0.06) 68 68 56 35 30 30 30 30 30 30 30 30 30 30 1.8 (0.06) 68 68 56 35 30 30 30 30 30 30 30 30 30 30 2 (0.07) 68 68 56 35 30 30 30 30 30 30 30 30 30 30
Engine speed (rpm)
Malfunction criteria Catalyst damage misfire judgment value Threshold value < Value of Map 2
GD(H6DO)-92

GENERAL DESCRIPTION
BO:DTC P0302 CYLINDER 2 MISFIRE DETECTED

NOTE: For the detection standard, refer to DTC P0301. <Ref. to GD(H6DO)-88, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
BP:DTC P0303 CYLINDER 3 MISFIRE DETECTED

BQ:DTC P0304 CYLINDER 4 MISFIRE DETECTED

BR:DTC P0305 CYLINDER 5 MISFIRE DETECTED

BS:DTC P0306 CYLINDER 6 MISFIRE DETECTED

GD(H6DO)-93

GENERAL DESCRIPTION
BT:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(A) (1) (2)
3. ENABLE CONDITION

GD(H6DO)-94

GENERAL DESCRIPTION
BU:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(A) (1) (2)
3. ENABLE CONDITION

GD(H6DO)-95

GENERAL DESCRIPTION
BV:DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2)

NOTE: For the detection standard, refer to DTC P0327. <Ref. to GD(H6DO)-94, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
BW:DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2)

NOTE: For the detection standard, refer to DTC P0328. <Ref. to GD(H6DO)-95, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-96

GENERAL DESCRIPTION
BX:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

Number of camshaft signal - 3 is normal at two engine revolution in a range of 0 CA - 0 CA. (A)
(B)
#1BTDC10 CA (C)
#6BTDC10 CA
#3BTDC10 CA
#2BTDC10 CA
#5BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
10 CA
30 CA
30 CA
EN-03092
(A)
(B)
(C)
Crankshaft signal
(1)
(3)
(2)
EN-02188
(1)
(2)
Crank sprocket
(3)
3. ENABLE CONDITION

GD(H6DO)-97

GENERAL DESCRIPTION
GD(H6DO)-98

GENERAL DESCRIPTION
BY:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/ PERFORMANCE

(B)
#1BTDC10 CA (C)
#6BTDC10 CA
#3BTDC10 CA
#2BTDC10 CA
#5BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
10 CA
30 CA
30 CA
EN-03092
(A)
(B)
(C)
Crankshaft signal
(1)
(3)
(2)
EN-02188
(1)
(2)
Crank sprocket
(3)
3. ENABLE CONDITION
GD(H6DO)-99

GENERAL DESCRIPTION

Malfunction Criteria Threshold Value Cylinder number identification Completed Amount of crank sensor signal during 1 rev. Not = 30
GD(H6DO)-100

GENERAL DESCRIPTION
BZ:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

(B)
#1BTDC10 CA (C)
#6BTDC10 CA
#3BTDC10 CA
#2BTDC10 CA
#5BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
10 CA
30 CA
30 CA
EN-03092
(A) Camshaft signal (RH)
(B) Camshaft signal (LH)
(C) Crankshaft signal
(1)
(3) (4)
(2)
EN-02190
(1) (2)
Throttle Camshaft plate
(3)
Detecting point
(4)
Camshaft one revolution (engine two revolutions)
3. ENABLE CONDITION
Secondary Parameters Battery voltage Enable Conditions t8V
GD(H6DO)-101

GENERAL DESCRIPTION

Abnormality Judgement 1 Judge as NG when the condition where the number of camshaft position sensor signals are less than 3 times during 2 engine speed. continues. Judgement Value
Malfunction Criteria Amount of camshaft sensor signal during 2 revs. Threshold Value < 3.000 time(s)
Time Needed for Diagnosis: Two engine revolutions 4 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement 1 Judge as OK and clear the NG when the malfunction criteria below are met. Judgement Value
Malfunction Criteria Camshaft position sensor signal Threshold Value t 3.000 time(s)
Time Needed for Diagnosis: Two engine revolutions Abnormality Judgement 2 If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgement Value
Malfunction Criteria Starter Camshaft position sensor signal Threshold Value ON No input
Time Needed for Diagnosis: 3000 ms Normality Judgement 2 Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction Criteria Camshaft position sensor signal Threshold Value Input exists
CA:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

NOTE: For the detection standard, refer to DTC P0340. <Ref. to GD(H6DO)-101, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-102

GENERAL DESCRIPTION
CB:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

Detect EGR system malfunction. Intake manifold pressure (negative pressure) is constant because the throttle valve is fully closed during deceleration fuel cut. At this time, when the EGR valve is opened/closed, the intake manifold pressure will change. EGR System OK/NG is judged by the range of this change.
(7)
(1) (6)
(2) (4) (3)
(5)
EN-02192
(1) (2) (3)
ECM Detecting circuit Switching circuit
(4) (5)
CPU EGR valve
(6) (7)
Main relay Battery power supply
GD(H6DO)-103

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Elapsed time after starting the engine Engine coolant temperature Engine speed Intake manifold pressure (absolute pressure) Ambient air temperature Throttle position Battery voltage Barometric pressure Vehicle speed Fuel shut-off function Neutral switch After neutral switch ON/OFF change No load change (A/C, power steering, lighting, rear defogger, heater fan and radiator fan) Enable Conditions t 40 s t 75 C(167 F) 1200 rpm 3250 rpm < 36.7 kPa (275 mmHg, 10.8 inHg) t 5 C(41 F) < 0.25 t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t53 km/h (32.9 MPH) In operation OFF t Value from Map t 5000 ms
Map
Engine coolant temperature C (F) After neutral switch change msec Engine coolant temperature C (F) After neutral switch change msec 40 (40) 0 30 (22) 0 20 (4) 0 10 (14) 0 0 (32) 0 10 (50) 0 20 (68) 0 30 (86) 0
40 (104) 0
50 (122) 0
60 (140) 0
70 (158) 0
80 (176) 0
90 (194) 0
100 (212) 0
110 (230) 0

During deceleration fuel cut from 53 km/h (approx. 33 MPH) or more, perform diagnosis once. Be careful of vehicle speed and engine speed. (Diagnosis will not be completed if the vehicle speed and engine speed conditions become out of specification due to deceleration.)
Measure the pressure values when the enable conditions are established, and perform diagnosis by calculating those results. 1. Label the intake manifold pressure value as PMOF1, which is observed when enable conditions are established, and set the EGR target step to 50 steps (nearly full open). 2. Label the intake manifold pressure value as PMON, which is observed after one second has passed since EGR target step was set to 50 steps (when the enable conditions were established), and set the EGR target step to 0. 3. Label the intake manifold pressure as PMOF2, which is observed after one second has passed since EGR target step was set to 0 (after two seconds have passed since the enable conditions were established). Abnormality Judgement Judge as NG when the following conditions are established. Judgement Value
Malfunction Criteria PMON (PMOF1 + PMOF2)/2 Threshold Value < 1.6 kPa (11.8 mmHg, 0.5 inHg)
Time Needed for Diagnosis: 1 time Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H6DO)-104

GENERAL DESCRIPTION
Start dignosis
(A)
(B)
(C)
Deceleration fuel cut
ON OFF
Diagnosis enable condition
(Open) EGR target step (Close)
(D)
(Open) EGR actual step (Close)
PMON
Intake manifold pressure (During normal condition)
PMOF2 PMOF1
DIagnostic mode timer
EN-05568
(A) (B)
2000 ms 1500 ms
(C)
1500 ms
(D)
50 step(s)
Malfunction Criteria PMON (PMOF1 + PMOF2)/2 Threshold Value t 1.6 kPa (11.8 mmHg, 0.5 inHg)
Time Needed for Diagnosis: 1 time
GD(H6DO)-105

GENERAL DESCRIPTION
CC:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

(1)
(2)
(A)
(3)
(B)
(3)
(C)
(D)
EN-01713
(A) (B) (1)
(C)
(D)
Output waveform from the front oxygen sensor Catalytic converter
(2)
(3)
GD(H6DO)-106

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters Battery voltage Atmospheric pressure Engine coolant temperature Estimated catalyst temperature Misfire detection every 200 rotations Learning value of evaporation gas density Sub feedback Evaporative system diagnosis Time of difference (< 0.10) between actual lambda and target lambda Vehicle speed Amount of intake air Enable Conditions t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t 75 C (167 F) t 560 C (1040 F) < 7 time(s) < 0.2 In operation Not in operation t 1000 ms
> 60 km/h (37.3 MPH) t 10 g/s (0.35 oz/s) and < 40 g/s (1.41 oz/s) Engine load change every 0.5 engine speed. < 0.02 g/rev (0 oz/rev) Rear oxygen output change from 660 mV or Experienced after fuel cut less to 660 mV or more Elapsed time after starting the engine t 205 s Purge execution calculated time t5s

Malfunction criteria 6 |(ro2sadn ro2sadn1)| / 6 |(sglmdn sglmdn1)| Threshold value > 25
Malfunction criteria 6 |(ro2sadn ro2sadn1)| / 6 |(sglmdn sglmdn1)| Threshold value d 25
GD(H6DO)-107

GENERAL DESCRIPTION
CD:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
(4) (1) (2) (3)
(5) (15)
(14) (16) (7) (9) (8) (10)
(13)
(12)
(11)
(6)
EN-04151
(1) (2) (3) (4) (5) (6)
Fuel gauge Intake manifold Throttle body Purge control solenoid valve Engine control module (ECM) Canister
(7) (8) (9) (10) (11)
Pressure control valve Drain valve Drain filter Shut-off valve Fuel temperature sensor
(12) (13) (14) (15) (16)
GD(H6DO)-108

GENERAL DESCRIPTION
0.04-inch Diagnosis
Mode Z
OK
Mode A
OK
Mode B
OK
Mode C
OK
Mode D NG
OK
Early OK
END
Cancel NG OK
NG
Mode Z Extend
EN-02872
Mode Mode Z (Purge control solenoid valve opening failure diagnosis) Mode A (Estimated evaporation amount) Mode B (Sealed negative pressure, large leakage judgement) Mode C (Pressure increase check, advanced OK judgement) Mode D (Negative pressure variation measurement, evaporation leakage diagnosis)
Mode Description Perform purge control solenoid valve opening failure diagnosis from the size of tank pressure variation from diagnosis start. Calculate the tank pressure change amount (P1). Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. If the tank pressure cannot be reduced, it is diagnosed as large leak. Wait until the tank pressure returns to the target (start level of P2 calculation). If the tank pressure does not become the value, make advanced OK judgement. Calculate the tank pressure variation (P2), and obtain the diagnostic value using P1 found in Mode A. Perform the evaporation diagnosis using the diagnostic value.
0 ms + 10000 ms

GD(H6DO)-109

GENERAL DESCRIPTION
0.02-inch Diagnosis
Mode A
OK
Mode B
OK
Mode C
OK
Mode D
OK
Mode E
EN-02871
Mode Description When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. Wait until the tank pressure returns to the target (start level of P2 calculation). Calculate the time it takes for the tank pressure to change to the Mode E shifting pressure. If the tank pressure does not change to the Mode E shifting pressure, make advanced OK judgement. Calculate the amount of evaporation (P1).
Diagnosis Period 0 Value of Map 1 0 Value of Map 2 0 20000 ms + 0 + Value from Map 2 0 0 ms + 200000 ms 0 0 ms + 200000 ms + Value from Map 3
Map1
Map2
Map 3
GD(H6DO)-110

GENERAL DESCRIPTION
(a) (1)
(4)
(b)
(c)
(2)
(3)
EN-01715
(a) (1) (2)
(b) (3)
Fuel tank Valve
(c) (4)
Canister Spring
GD(H6DO)-111

GENERAL DESCRIPTION
A (a)
B (b)
C (c)
EN-01716
(a)
(b)
(c)
Canister
A (a)
B (b)
C (c)
EN-01717
(a)
Barometric pressure
(b)
Fuel tank
(c)
Canister
GD(H6DO)-112

GENERAL DESCRIPTION
A (a)
B (b)
C (c)
(1) EN-01718
(a) (1)
(b)
Fuel tank
(c)
Canister
When Solenoid is ON
A (a)
B (b)
C (c)
EN-01719
(a)
Barometric pressure
(b)
Fuel tank
(c)
Canister
GD(H6DO)-113

GENERAL DESCRIPTION
EN-02293
3. ENABLE CONDITION
0.04-inch Diagnosis
Secondary Parameters Battery voltage Barometric pressure Total time of canister purge operation Elapsed time after starting the engine Learning value of evaporation gas density Engine speed Fuel tank pressure Intake manifold relative vacuum (relative pressure) Vehicle speed Fuel level Enable Conditions t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg) t 120000 ms t 856 s < 0.08 1050 rpm 6500 rpm t 4 kPa (30 mmHg, 1.2 inHg) t 26.7 kPa ( 200 mmHg, 7.9 inHg) t 32 km/h (19.9 MPH) 9.6 2 (2.54 US gal, 2.11 Imp gal) 54.4 2 (14.37 US gal, 11.97 Imp gal) Closed air/fuel ratio control In operation Fuel temperature 10 C (14 F) 45 C (113 F) Intake air temperature t 10 C (14 F) Pressure change every one second < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) Minimum pressure change value every one sec- < 1.7 mmHg (Mode A) ond Maximum pressure change value every one second < 1.7 mmHg (Mode D) Change of fuel level per 128 milliseconds < 2 2 (0.53 US gal, 0.44 Imp gal) Air fuel ratio 0.76 1.25
GD(H6DO)-114

GENERAL DESCRIPTION
0.02-inch Diagnosis
Secondary Parameters At starting a diagnosis Evap. diagnosis Battery voltage Barometric pressure Time since last incomplete 0.02-inch leakage diagnosis When cancelling in mode A When cancelling in other than mode A Total time of canister purge operation Elapsed time after starting the engine Fuel temperature Fuel level Enable Conditions Incomplete t 10.9 V t 75 kPa (563 mmHg, 22.2 inHg)
> 120000 ms > 600000 ms t 120000 ms t 120 s 10 C (14 F) 55 C (131 F) 9.6 2 (2.54 US gal, 2.11 Imp gal) 54.4 2 (14.37 US gal, 11.97 Imp gal) Intake manifold relative vacuum (relative pressure) t 8 kPa ( 60 mmHg, 2.4 inHg) Fuel tank pressure 0.7 kPa (5 mmHg, 0.2 inHg) 1.4 kPa (10.7 mmHg, 0.4 inHg) Vehicle speed 50 km/h (31.1 MPH) 510 km/h (316.9 MPH) continues for 125000 ms Closed air/fuel ratio control In operation Engine speed 1050 rpm 7000 rpm During diagnosis Change of fuel level d Value of Map 4 Pressure change every one second Minimum pressure change value every one second Maximum pressure change value every one second | Pressure change in tank every second | Barometric pressure change < 0.1 kPa (0.44 mmHg, 0 inHg) < 0.1 kPa (0.51 mmHg, 0 inHg) (Mode D)
d 0.1 kPa (0.75 mmHg, 0 inHg) 0.5 kPa (3.6 mmHg, 0.1 inHg) 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode D) 0.3 kPa (2.4 mmHg, 0.1 inHg) 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode E)
Map4

GD(H6DO)-115

GENERAL DESCRIPTION
Purge control solenoid valve stuck open fault diagnosis DTC P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Purpose of Mode Z When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled. DIAGNOSTIC METHOD Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z. Abnormality Judgement If OK judgment cannot be made, extend Mode Z, and Judge as NG when the following conditions are established after predetermined amount of time. Judgement Value
Malfunction criteria evptez evptezha evptezini Time of 2 2 (0.53 US gal, 0.44 Imp gal) or more fuel no sloshing Threshold value > 0.6 kPa (4.5 mmHg, 0.2 inHg) d 1.4 kPa (10.7 mmHg, 0.4 inHg) t 40000 ms DTC P0457
Time Needed for Diagnosis: 0 ms + 3000 ms + 13000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. When judgment for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis. Cancel the evaporative diagnosis when the OK/NG judgment for purge control solenoid valve stuck open cannot be made in Mode Z. Normality Judgement Judge as OK and change to Mode A when the following conditions are established after predetermined time has passed since Mode Z started. Judgement Value
Malfunction criteria evptez evptezha Threshold value d 0.4 kPa (3 mmHg, 0.1 inHg) DTC P0457
GD(H6DO)-116

GENERAL DESCRIPTION
Normal
(1)
(2)
(3) 0 (4)
(5) EN-02869
(1) (2)
Mode Z 3000 ms
(3) (4)
(5)
OK judgment
GD(H6DO)-117

GENERAL DESCRIPTION
(1) (3) (6) evptez
(2)
(4) 0
evptezini
(5)
evptezha
(7)
(8)
EN-02870
(1) (2) (3)
(4) (5) (6)
(7) (8)
40000 ms no fuel sloshing NG judgment
GD(H6DO)-118

GENERAL DESCRIPTION
Leak Diagnosis DTC P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. The diagnosis is divided into the following five phases. Mode A: (Estimated evaporation gas amount) Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B. Mode B: (Negative pressure sealed) Introduce negative pressure in the intake manifold to the tank. Approx. 0 o 1.4 kPa (0 o 10.5 mmHg, 0 o 0.4 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage in the system and terminate the evaporative emission control system diagnosis. Abnormality Judgement Judge as NG (large leakage) when the following conditions are established. Judgement Value
Malfunction criteria Time to reach target negative pressure or Mode B time (Min. pressure value in tank when in mode B) (Tank pressure when mode B started) Threshold value DTC t 10000 ms + 25000 ms P0457 t 10000 ms > 0.3 kPa (2.5 mmHg, 0.1 inHg)
Tank pressure when starting calTime for advanced OK culation of P2 judgment 1.3 kPa (9.75 mmHg, 0.4 inHg) 17000 ms
Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 17000 ms
GD(H6DO)-119

GENERAL DESCRIPTION
Mode D: (Measure amount of negative pressure change) Monitor the tank pressure change amount when using mode D. In this case, the tank pressure increases, (nears barometric pressure) because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2. After calculating P2, perform a small leak diagnosis according to the items below. When Mode D is ended Assign tank variations measured in Mode A and Mode D, P1 and P2, to the formula below, judge small leaks in the system. If the measured judgment value exceeds the threshold value, it is judged to be a malfunction. Abnormality Judgement Judge as NG when the following conditions are established within the predetermined time. Judge as OK and clear the NG if the following conditions are not established within the predetermined time. Judgement Value

Fuel temperature vs. Fuel level 25 C (77 F) 30 C (86 F) 35 C (95 F) 40 C (104 F) 45 C (113 F) 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0 2 (0 US gal, 0 Imp gal) (2.1 mmHg, (2.2 mmHg, (2.3 mmHg, (2.35 mmHg, (2.4 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 10 2 (2.64 US gal, 2.2 Imp gal) (2.1 mmHg, (2.2 mmHg, (2.3 mmHg, (2.35 mmHg, (2.4 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.4 kPa 20 2 (5.28 US gal, 4.4 Imp gal) (2.3 mmHg, (2.4 mmHg, (2.5 mmHg, (2.6 mmHg, (2.7 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 30 2 (7.93 US gal, 6.6 Imp gal) (2.9 mmHg, (3.05 mmHg, (3.15 mmHg, (3.25 mmHg, (3.35 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.5 kPa 0.4 kPa 0.5 kPa 0.4 kPa 0.4 kPa (3.4 mmHg, 40 2 (10.57 US gal, 8.8 Imp gal) (2.9 mmHg, (3.15 mmHg, (3.3 mmHg, (3.5 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.4 kPa 0.4 kPa 0.5 kPa (3.5 mmHg, (3.6 mmHg, (3.7 mmHg, 50 2 (13.21 US gal, 11 Imp gal) (3.2 mmHg, (3.3 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.5 kPa 60 2 (15.85 US gal, 13.2 Imp gal) (3.2 mmHg, (3.3 mmHg, (3.5 mmHg, (3.6 mmHg, (3.7 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg)
GD(H6DO)-120

GENERAL DESCRIPTION
Leak Diagnosis DTC P0456 Evaporative Emission Control System Leak Detected (very small leak) The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. The diagnosis is divided into the following five phases. Mode A: (0 point compensation) When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Shift to mode B when returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time. Mode B: (Negative pressure introduced) Introduce negative pressure in the intake manifold to the tank. Approx. 0 o 2 kPa (0 o 15 mmHg, 0 o 0.6 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. When the tank internal pressure does not reach the target negative pressure, the diagnosis is cancelled. Mode C: (Negative pressure maintained) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed. Mode D: (Calculate the amount of negative pressure change) Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time (evpdset) for the tank pressure to change to the Mode E shifting pressure. When the Mode E shifting pressure is reached, Mode E is entered. If it does not change to the Mode E shifting pressure after the predetermined amount of time has passed, make advanced OK judgment or cancel the diagnosis. Normality Judgement Judge as OK when the following conditions are established. Judgement Value
Malfunction criteria Advanced OK judgment 1 Mode D time Tank internal pressure Advanced OK judgment 2 Mode D time P2 Threshold value t 0 ms + 20000 ms d Value of Map 6 t 0 ms + 200000 ms d Value of Map 7
Map6
Map7
GD(H6DO)-121

GENERAL DESCRIPTION
Malfunction criteria P1 Threshold value < Value of Map 8

Time (evpdset) vs. Fuel level 0 2 (0 US gal, 0 Imp gal) 0 ms 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg) 30000 ms 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 0.1 kPa (0.5 mmHg, 0 inHg) 50000 ms 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.7 mmHg, 0.1 inHg) 0.2 kPa (1.85 mmHg, 0.1 inHg) 0.3 kPa (2 mmHg, 0.1 inHg) 0.3 kPa (2 mmHg, 0.1 inHg) 100000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 160000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 0.3 kPa (2.3 mmHg, 0.1 inHg) 200000 ms 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.4 kPa (2.7 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0 kPa (0 mmHg, 0 inHg) 0 kPa (0 mmHg, 0 inHg)
10 2 (2.64 US gal, 2.2 Imp gal)
20 2 (5.28 US gal, 4.4 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)
40 2 (10.57 US gal, 8.8 Imp gal)
50 2 (13.21 US gal, 11 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
Time Needed for Diagnosis: Value of Map1+ Value of Map2 + 20000 ms + 0 + Value of Map2 + 0 ms + 200000 ms + Value of Map3 + 0 ms + 200000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H6DO)-122

GENERAL DESCRIPTION
Malfunction criteria P1 Threshold value > Value of Map 9

Time (evpdset) vs. Fuel level 0 2 (0 US gal, 0 Imp gal) 0 ms 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 0.1 kPa (1 mmHg, 0 inHg) 30000 ms 0.5 kPa (3.5 mmHg, 0.1 inHg) 0.5 kPa (3.5 mmHg, 0.1 inHg) 0.4 kPa (3.25 mmHg, 0.1 inHg) 0.4 kPa (3 mmHg, 0.1 inHg) 0.3 kPa (2.25 mmHg, 0.1 inHg) 0.2 kPa (1.5 mmHg, 0.1 inHg) 0.2 kPa (1.5 mmHg, 0.1 inHg) 50000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 100000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 160000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 200000 ms 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.6 kPa (4.2 mmHg, 0.2 inHg) 0.5 kPa (4.1 mmHg, 0.2 inHg) 0.5 kPa (3.9 mmHg, 0.2 inHg) 0.5 kPa (3.4 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg)
10 2 (2.64 US gal, 2.2 Imp gal)
20 2 (5.28 US gal, 4.4 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)
40 2 (10.57 US gal, 8.8 Imp gal)
50 2 (13.21 US gal, 11 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
Time Needed for Diagnosis: Value of Map1+ Value of Map2 + 20000 ms + 0 + Value of Map2 + 0 ms + 200000 ms + Value of Map3 + 0 ms + 200000 ms
GD(H6DO)-123

GENERAL DESCRIPTION
CE:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION

GD(H6DO)-124

GENERAL DESCRIPTION
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal Threshold value t 10.9 V t 1 second Low
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal Threshold value t 10.9 V t 1 second High
GD(H6DO)-125

GENERAL DESCRIPTION
CF:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION

GD(H6DO)-126

GENERAL DESCRIPTION
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal Threshold value t 10.9 V t 1 second High
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal Threshold value t 10.9 V t 1 second Low
GD(H6DO)-127

GENERAL DESCRIPTION
CG:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION

GD(H6DO)-128

GENERAL DESCRIPTION
< 0 kPa (0.375 mmHg, 0 inHg) t 7 C (44.6 F)
If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is less than 2 2 (0.53 US gal, 0.44 Imp gal), extend 60 s and make judgement with the Max. and Min. values for the fuel level in 60 s 2. If a difference does not appear, extend the time (60 s 3, 60 s 4, 60 s 5) and continue the judgement. If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more, the diagnosis counter counts up. Time Needed for Diagnosis: 60 s 16 time(s) or more Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
GD(H6DO)-129

GENERAL DESCRIPTION
CH:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION

GD(H6DO)-130

GENERAL DESCRIPTION
Malfunction criteria Fuel tank pressure Battery voltage Threshold value < 7.4 kPa (55.85 mmHg, 2.2 inHg) t 10.9 V
Malfunction criteria Fuel tank pressure Battery voltage Threshold value t 7.4 kPa (55.85 mmHg, 2.2 inHg) t 10.9 V
GD(H6DO)-131

GENERAL DESCRIPTION
CI: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
(A) (1) (2)
(B) (C)
EN-04462
(A) (1)
(B) (2)
(C)
To fuel tank
3. ENABLE CONDITION

GD(H6DO)-132

GENERAL DESCRIPTION
Malfunction criteria Fuel tank pressure Fuel temperature Barometric pressure Threshold value t 8 kPa (59.85 mmHg, 2.4 inHg) < 35 C (95 F) t 75 kPa (563 mmHg, 22.2 inHg)
Malfunction Criteria Fuel tank pressure Threshold Value < 8 kPa (59.85 mmHg, 2.4 inHg)
CJ:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
NOTE: For the detection standard, refer to DTC P0442. <Ref. to GD(H6DO)-108, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CK:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
For the detection standard, refer to DTC P0442. <Ref. to GD(H6DO)-108, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-133

GENERAL DESCRIPTION
CL:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
(B) (A)
EN-02197
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION

GD(H6DO)-134

GENERAL DESCRIPTION
Malfunction criteria Duty ratio of ON Terminal output voltage Threshold value < 0.75 Low
GD(H6DO)-135

GENERAL DESCRIPTION
CM:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
(B) (A)
EN-02197
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION

GD(H6DO)-136

GENERAL DESCRIPTION
Malfunction criteria Duty ratio of ON Terminal output voltage Threshold value t 0.25 High
GD(H6DO)-137

GENERAL DESCRIPTION
CN:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

(A)
(B)
EN-01734
(A)
Fuel level
(B)
Resistance
3. ENABLE CONDITION

GD(H6DO)-138

GENERAL DESCRIPTION
Malfunction criteria Accumulated amount of intake air Max. min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine Threshold value t 330957 g (11672.85 oz) < 2.6 2 (0.69 US gal, 0.57 Imp gal) t 10.9 V < 6500 rpm t 5000 ms
Malfunction criteria Accumulated amount of intake air Max. min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine Threshold value t 330957 g (11672.85 oz) t 2.6 2 (0.69 US gal, 0.57 Imp gal) t 10.9 V < 6500 rpm t 5000 ms
GD(H6DO)-139

GENERAL DESCRIPTION
CO:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

(1)
(5)
(4)
(2)
(3)
EN-05371
(1) (2)
(3) (5)
(4)
Detecting circuit
3. ENABLE CONDITION

GD(H6DO)-140

GENERAL DESCRIPTION
Malfunction criteria Battery voltage Elapsed time after starting the engine Output voltage Threshold value t 10.9 V t 3000 ms < 0.173 V
Malfunction criteria Battery voltage Elapsed time after starting the engine Output voltage Threshold value t 10.9 V t 3000 ms t 0.173 V
GD(H6DO)-141

GENERAL DESCRIPTION
CP:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

(1)
(5)
(4)
(2)
(3)
EN-05371
(1) (2)
(3) (5)
(4)
Detecting circuit
3. ENABLE CONDITION

GD(H6DO)-142

GENERAL DESCRIPTION
Malfunction criteria Battery voltage Elapsed time after starting the engine Output voltage Threshold value t 10.9 V t 3000 ms t 7.212 V
Malfunction criteria Battery voltage Elapsed time after starting the engine Output voltage Threshold value t 10.9 V t 3000 ms < 7.212 V
GD(H6DO)-143

GENERAL DESCRIPTION
CQ:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

2. ENABLE CONDITION

GD(H6DO)-144

GENERAL DESCRIPTION
Diagnosis condition
(A)
Diagnosis timer
(C) (D)
(B) EN-05569
(A) (B)
(C)
Malfunction
(D)
Normal
GD(H6DO)-145

GENERAL DESCRIPTION
Map
Maximum value Minimum value of change of tank pressure for 12288 ms Maximum value Minimum value of battery voltage for12288 ms t 0 kPa (0.375031 mmHg, 0 inHg) t 0.609 V
GD(H6DO)-146

GENERAL DESCRIPTION
CR:DTC P0500 VEHICLE SPEED SENSOR A

3. ENABLE CONDITION

GD(H6DO)-147

GENERAL DESCRIPTION
CS:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
2. ENABLE CONDITION

GD(H6DO)-148

GENERAL DESCRIPTION
CT:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION

GD(H6DO)-149

GENERAL DESCRIPTION
CU:DTC P0512 STARTER REQUEST CIRCUIT

2. ENABLE CONDITION

Malfunction criteria Engine condition Starter OFF signal Battery voltage Threshold value After engine starting Not detected t8V
Malfunction criteria Starter OFF signal Battery voltage Threshold value Detected t8V
GD(H6DO)-150

GENERAL DESCRIPTION
CV:DTC P0513 INCORRECT IMMOBILIZER KEY

DTC P0513 P1570 P1571 P1572 P1574 P1576 P1577 P1578 Item Incorrect Immobilizer Key Antenna Reference Code Incompatibility IMM Circuit Failure (Except Antenna Circuit) Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Outline of diagnosis Incorrect immobilizer key (Use of unregistered key in body integrated unit) Faulty antenna Reference code incompatibility between body integrated unit and ECM Communication failure between body integrated unit and ECM Failure of body integrated unit to verify key (transponder) ID code or transponder failure ECM malfunctioning Body integrated unit malfunctioning Reference code incompatibility between body integrated unit and combination meter
2. ENABLE CONDITION

GD(H6DO)-151

GENERAL DESCRIPTION
CW:DTC P0600 SERIAL COMMUNICATION LINK

3. ENABLE CONDITION

GD(H6DO)-152

GENERAL DESCRIPTION
GD(H6DO)-153

GENERAL DESCRIPTION
CX:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
2. ENABLE CONDITION

Malfunction criteria Write the specified value to RAM and then read. Threshold value The written value cannot be read.
Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction criteria Write the specified value to RAM and then read. Threshold value The written value can be read.
GD(H6DO)-154

GENERAL DESCRIPTION
CY:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
2. ENABLE CONDITION

Malfunction criteria SUM value of ROM Threshold value Standard
Time Needed for Diagnosis: Main CPU: 16 milliseconds 32 time(s) Sub CPU: 16 milliseconds 2 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction criteria SUM value of ROM Threshold value Standard
Time Needed for Diagnosis: Main CPU: 16 milliseconds 125 time(s) Sub CPU: 16 milliseconds 2 time(s)
GD(H6DO)-155

GENERAL DESCRIPTION
CZ:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE

Judge as NG when any one of the followings is established. (1) When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU. (2) When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and sub CPU. (3) When the sub CPU operates abnormally. (4) When the communication between main CPU m o sub CPU is abnormal. (5) When the input amplifier circuit of throttle position sensor 1 is abnormal. (6) When the cruise control cannot be canceled correctly. (7) When the signal of brake SW1 and 2 is mismatched.
(12) (1)
(2) (11) (10)
(13) (10) (3)
(4) (5)
(10) (14)
(6) (10)
(7) (8) (9) EN-01862
(1) (2) (3) (4) (5)
(6) (7) (8) (9) (10)
(11) (12) (13) (14)
GD(H6DO)-156

GENERAL DESCRIPTION
3. ENABLE CONDITION
Secondary Parameters (1) Ignition switch (1) Battery voltage (2) Ignition switch (2) Battery voltage (3) Ignition switch (3) Battery voltage (4) Ignition switch (4) Battery voltage (5) Throttle opening angle (5) Ignition switch (5) Battery voltage (6) Brake switch (only with cruise control) (6) Ignition switch (6) Battery voltage (7) Ignition switch (7) Battery voltage Enable Conditions ON t6V ON t6V ON t6V ON t6V ON t6V ON ON t6V ON t6V

(1) (4): Always perform the diagnosis continuously. (5): Always perform the diagnosis continuously when idling. (6): Perform the diagnosis when the brake pedal is depressed. (7): Always perform the diagnosis continuously.
GD(H6DO)-157

GENERAL DESCRIPTION
Malfunction Criteria (1) Difference of CPU reading value of the throttle position sensor signal (2) Difference of CPU read value of the accelerator pedal position sensor signal (3) WD pulse from sub CPU (4) Communication between CPU (5) |Throttle position sensor 1 opening angle (Throttle position sensor 1 opening angle after passing amplifier) 1/4| (6) Cruise control cancel signal at brake ON (7) Brake switch 1, 2 signal Threshold Value t 0.4058 V t 0.127542424 V No WD pulse occur Not possible to communicate t3
Cruise control cancel signal OFF SW 1 and 2 are not matched
Time Needed for Diagnosis: (1): 600 ms (2): 830 ms (3): 200 ms (4): 200 ms (5): 24 ms (6): 250 ms (7): 200 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction Criteria (1) Difference of CPU reading value of the throttle position sensor signal (2) Difference of CPU read value of the accelerator pedal position sensor signal (3) WD pulse from sub CPU (4) Communication between CPU (5) |Throttle position sensor 1 opening angle (Throttle position sensor 1 opening angle after passing amplifier) 1/4| (6) Cruise control cancel signal at brake ON (7) Brake switch 1, 2 signal Threshold Value < 0.4058 V < 0.127542424 V WD pulse occur Possible to communicate <3
Cruise control cancel signal ON SW 1 and 2 are matched
Time Needed for Diagnosis: (1): 2000 ms (2): 2000 ms (3): 2000 ms (4): 2000 ms (5): 24 ms (6): 2000 ms (7): 2000 ms
GD(H6DO)-158

GENERAL DESCRIPTION
DA:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)

(3)
(1)
(4)
(2)
EN-01863
(1) (2)
(3)
(4)
Drive circuit
3. ENABLE CONDITION
Secondary Parameters Normal operation of electronic throttle control Enable Conditions ON

GD(H6DO)-159

GENERAL DESCRIPTION
Malfunction criteria Difference between target opening angle and actual opening angle Output duty to drive circuit Threshold value t Value of Map 1 t 95%
Map1
Target throttle opening angle () = d Difference between target opening angle and actual opening angle () 0 d d < 6.15 3.5 6.15 d d < 9.65 5 9.65 d d < 14.65 12 14.65 d d < 26.65 25 26.65 d d 25
Time Needed for Diagnosis: Difference between target opening angle and actual opening angle: 1000 milliseconds (when target opening angle > actual opening angle) or value of Map 2 (when target opening angle d actual opening angle) Output duty to drive circuit: value of Map 3 Map2
Throttle position sensor 1 opening angle () = d Judgement time (milliseconds) 0 d d < 5.5 1000 5.5 d d < 9 400 9 d d < 13 300 13 d d < 22 250 22 d d 250
Map 3
Voltage to drive circuit (V) Judgement time (milliseconds) 6 2000 8 2000 10 2000 12 2000 14 2000 16 2000
Malfunction criteria Difference between target opening angle and actual opening angle Output duty to drive circuit Threshold value < Value of Map 1 < 95%
Time Needed for Diagnosis: Difference between target opening angle and actual opening angle: 2000 ms Output duty to drive circuit: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.
GD(H6DO)-160

GENERAL DESCRIPTION
DB:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

2. ENABLE CONDITION

Malfunction criteria Battery voltage MIL lighting request from TCM Threshold value t 10.9 V Yes
Malfunction criteria Battery voltage MIL lighting request from TCM Threshold value t 10.9 V None
GD(H6DO)-161

GENERAL DESCRIPTION
DC:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
GD(H6DO)-162

GENERAL DESCRIPTION
3. ENABLE CONDITION

Malfunction criteria O value Threshold value < 0.85
Malfunction criteria O value Threshold value t 0.85
GD(H6DO)-163

GENERAL DESCRIPTION
DD:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)

(3) (1)
(A)
(2)
(2)
(C) (4)
(B)
(D)
EN-01693
(A) (B) (1) (2)
(C)
Lean
(D)
Rich
(3)
ZrO2
(4)
Ceramic heater
GD(H6DO)-164

GENERAL DESCRIPTION
3. ENABLE CONDITION

Malfunction criteria O value Threshold value > 1.15
Malfunction criteria O value Threshold value d 1.15
GD(H6DO)-165

GENERAL DESCRIPTION
DE:DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P1152. <Ref. to GD(H6DO)-162, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
DF:DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1)

NOTE: For the detection standard, refer to DTC P1153. <Ref. to GD(H6DO)-164, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-166

GENERAL DESCRIPTION
DG:DTC P1160 RETURN SPRING FAILURE

(1) (3)
(8)
(2)
S S
(7) (6) (4)
(5)
EN-04463
(1) (2) (3)
(4) (5) (6)
(7) (8)
DC motor Main and sub throttle position sensor
3. ENABLE CONDITION
Secondary Parameters Battery voltage Throttle position sensor Enable Conditions t6V Normal

GD(H6DO)-167

GENERAL DESCRIPTION
Malfunction criteria Opening variation after continuity is set to OFF Threshold value <2
Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the following conditions are established. Judgement Value
Malfunction criteria Opening variation after continuity is set to OFF Threshold value t2
GD(H6DO)-168

GENERAL DESCRIPTION
DH:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
(1)
(A) (2) (3) (4)
(B)
(C)
(5) EN-01759
(A) (1) (2)
(B) (3) (4)
(C) (5)
To fuel tank Valve
3. ENABLE CONDITION

GD(H6DO)-169

GENERAL DESCRIPTION
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal Threshold value t 10.9 V t 1 second Low
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal Threshold value t 10.9 V t 1 second High
GD(H6DO)-170

GENERAL DESCRIPTION
DI: DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
(1)
(A) (2) (3) (4)
(B)
(C)
(5) EN-01759
(A) (1) (2)
(B) (3) (4)
(C) (5)
To fuel tank Valve
3. ENABLE CONDITION

GD(H6DO)-171

GENERAL DESCRIPTION
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal Threshold value t 10.9 V t 1 second High
Malfunction criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal Threshold value t 10.9 V t 1 second Low
GD(H6DO)-172

GENERAL DESCRIPTION
DJ:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

(19) (14) (15) (16) (8) (7) (4) (5) (6) (19) (18)
( 9 ) (10)
(11)
(12)
(13)
(17)
(2) (1)
(3)
EN-02294
(1) (2) (3) (4) (5) (6) (7)
(8) (9) (10) (11) (12) (13)
(14) (15) (16) (17) (18) (19)
3. ENABLE CONDITION

GD(H6DO)-173

GENERAL DESCRIPTION
Malfunction Criteria Fuel tank pressure Cumulative time when all the malfunction criteria below are met. Purge control solenoid valve duty Fuel temperature Intake manifold relative pressure Threshold Value > 4 kPa (30 mmHg, 1.2 inHg) t 30000 ms Not = 0 10 C (14 F) 55 C (131 F) t 26.7 kPa (200 mmHg, 7.9 inHg)
GD(H6DO)-174

GENERAL DESCRIPTION
DK:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
(5)
(1) (6)
(3) (2) (4)
EN-02051
(1) (2)
(3) (4)
(5) (6)
3. ENABLE CONDITION

Perform diagnosis continuously during EGR operation.
GD(H6DO)-175

GENERAL DESCRIPTION
Malfunction Criteria Terminal voltage level when ECM outputs OFF signal Threshold Value Low level
Malfunction Criteria Terminal voltage level when ECM outputs OFF signal Threshold Value High level
Time Needed for Diagnosis:4 ms 2 time(s)
GD(H6DO)-176

GENERAL DESCRIPTION
DL:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
(5)
(1) (6)
(3) (2) (4)
EN-02051
(1) (2)
(3) (4)
(5) (6)
3. ENABLE CONDITION

GD(H6DO)-177

GENERAL DESCRIPTION
Malfunction Criteria Terminal voltage level when ECM outputs ON signal Threshold Value High level
Malfunction Criteria Terminal voltage level when ECM outputs ON signal Threshold Value Low level
Time Needed for Diagnosis:4 ms 2 time(s)
GD(H6DO)-178

GENERAL DESCRIPTION
DM:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
NOTE: For the detection standard, refer to DTC P1492. <Ref. to GD(H6DO)-175, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
DN:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
NOTE: For the detection standard, refer to DTC P1493. <Ref. to GD(H6DO)-177, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
DO:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
DP:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
DQ:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
DR:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
GD(H6DO)-179

GENERAL DESCRIPTION
DS:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

2. ENABLE CONDITION

GD(H6DO)-180

GENERAL DESCRIPTION
DT:DTC P1570 ANTENNA

NOTE: For the detection standard, refer to DTC P0513. <Ref. to GD(H6DO)-151, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
DU:DTC P1571 REFERENCE CODE INCOMPATIBILITY

DV:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

DW:DTC P1574 KEY COMMUNICATION FAILURE

DX:DTC P1576 EGI CONTROL MODULE EEPROM

DY:DTC P1577 IMM CONTROL MODULE EEPROM

DZ:DTC P1578 METER FAILURE

GD(H6DO)-181

GENERAL DESCRIPTION
EA:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

2. ENABLE CONDITION

GD(H6DO)-182

GENERAL DESCRIPTION
Exhaust gas temperature diagnosis Abnormality Judgement Calculate the estimated exhaust gas temperature when the diagnostic enable condition is established. Judge as NG when the following conditions are established after engine starting within the predetermined time. Judgement Value
Malfunction criteria Estimated exhaust gas temperature Threshold value < Value from Map
Map
Coolant temperature after starting the engine Threshold Value 40 C (40 F) 0 C (32 F) 30 C (22 F) 0 C (32 F) 20 C (4 F) 0 C (32 F) 10 C (14 F) 0 C (32 F) 0 C (32 F) 155 C (311 F) 10 C (50 F) 150 C (302 F) 20 C (68 F) 155 C (311 F) 30 C (86 F) 40 C (104 F) 50 C (122 F)
140 C 133 C 130 C (284 F) (271.4 F) (266 F)
Malfunction criteria Estimated exhaust gas temperature Threshold value t Value from Map
Time Needed for Diagnosis: Less than 1 second Idle speed diagnosis Abnormality Judgement Judge as NG when the following conditions are established after the predetermined time. Judgement Value
Malfunction criteria Continuous time of (Target engine speed Actual engine speed > 200 rpm) Continuous time of (actual retard amount > 20 CA) Threshold value t 6000 ms t 0 ms
Malfunction criteria Continuous time of (Target engine speed Actual engine speed > 200 rpm) Continuous time of (actual retard amount > 20 CA) Threshold value < 6000 ms < 0 ms
GD(H6DO)-183

GENERAL DESCRIPTION
EB:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
Detect open or short circuit of the oil flow control solenoid valve. Judge as NG when the current is small even though the duty signal is large.
2. ENABLE CONDITION

Malfunction criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current Threshold value t 10.9 V t 99.61 % < 0.306 A
Malfunction criteria Threshold value Battery voltage t 10.9 V Target current value of the oil flow control t 0.14 A solenoid valve |Target current value of the oil flow con< 0.08 A trol solenoid valve Oil flow control solenoid valve control current value|
GD(H6DO)-184

GENERAL DESCRIPTION
EC:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
Detect open or short circuit of oil flow control solenoid valve. Judge as NG when the current is large even though the duty signal is small.
2. ENABLE CONDITION

Malfunction criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current Threshold value t 10.9 V < 0.39 % t 0.306 A
Malfunction criteria Threshold value Battery voltage t 10.9 V |Target current value of the oil flow con< 0.08 A trol solenoid valve Oil flow control solenoid valve control current value|
GD(H6DO)-185

GENERAL DESCRIPTION
ED:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
NOTE: For the detection standard, refer to DTC P2088. <Ref. to GD(H6DO)-184, DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
EE:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
NOTE: For the detection standard, refer to DTC P2089. <Ref. to GD(H6DO)-185, DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-186

GENERAL DESCRIPTION
EF:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION

GD(H6DO)-187

GENERAL DESCRIPTION
Malfunction criteria Sub feedback learning value Threshold value < 0.03
Malfunction criteria Sub feedback learning value Threshold value t 0.03 + 0
GD(H6DO)-188

GENERAL DESCRIPTION
EG:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
(E) (3) V (1)
(A)
(F)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A) (B) (1)
(C) (D) (2)
(E) (F) (3)
3. ENABLE CONDITION

GD(H6DO)-189

GENERAL DESCRIPTION
Malfunction criteria Sub feedback learning value Threshold value t 0.04
Malfunction criteria Sub feedback learning value Threshold value < 0.04 + 0
EH:DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2
NOTE: For the detection standard, refer to DTC P2096. <Ref. to GD(H6DO)-187, DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
EI: DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2
NOTE: For the detection standard, refer to DTC P2097. <Ref. to GD(H6DO)-189, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H6DO)-190

GENERAL DESCRIPTION
EJ:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE

12V (1) 12V
(6)
(2)
(3)
(4)
(7)
(2)
(5) EN-01867
(1) (2) (3)
(4) (5)
(6) (7)
3. ENABLE CONDITION
Secondary Parameters Under control of electronic throttle control CPU communication line sub o main normal judgment Enable Conditions ON Normal

GD(H6DO)-191

GENERAL DESCRIPTION
Malfunction criteria Motor current or Drive circuit inner temperature Threshold value >8A > 175C (347F)
GD(H6DO)-192

GENERAL DESCRIPTION
EK:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

12V (1) 12V
(4)
(2)
(3)
(5)
EN-01868
(1) (2)
(3) (4)
(5)
Motor
3. ENABLE CONDITION
Secondary Parameters Battery voltage Electronic throttle control relay output Enable Conditions t 11 V ON

GD(H6DO)-193

GENERAL DESCRIPTION
Malfunction criteria Motor power voltage Threshold value d5V
Malfunction criteria Motor power voltage Threshold value >5V
GD(H6DO)-194

GENERAL DESCRIPTION
EL:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

12V (1) 12V
(4)
(2)
(3)
(5)
EN-01868
(1) (2)
(3) (4)
(5)
Motor
3. ENABLE CONDITION
Secondary Parameters Battery voltage Electronic throttle control relay output Enable Conditions t6V OFF

GD(H6DO)-195

GENERAL DESCRIPTION
Malfunction criteria Motor power voltage Threshold value t5V
Malfunction criteria Motor power voltage Threshold value <5V
GD(H6DO)-196

GENERAL DESCRIPTION
EM:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE

(1)
(3)
(2)
(4)
EN-01869
(1) (2)
(3)
Motor
(4)
3. ENABLE CONDITION

GD(H6DO)-197

GENERAL DESCRIPTION
Malfunction criteria Throttle sensor opening angle at full close point learning Threshold value < 10.127 or > 19.872 or Throttle opening angle when the ignition switch is ON Throttle minimum stop position < 1.683
Time Needed for Diagnosis: 8 ms 80 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgement Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgement Value
Malfunction criteria Throttle sensor opening angle at full close point learning Threshold value t 10.127 and d 19.872 t 1.683
Throttle opening angle when the ignition switch is ON Throttle minimum stop position
GD(H6DO)-198

GENERAL DESCRIPTION
EN:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H6DO)-199

GENERAL DESCRIPTION
GD(H6DO)-200

GENERAL DESCRIPTION
EO:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H6DO)-201

GENERAL DESCRIPTION
GD(H6DO)-202

GENERAL DESCRIPTION
EP:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H6DO)-203

GENERAL DESCRIPTION
GD(H6DO)-204

GENERAL DESCRIPTION
EQ:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H6DO)-205

GENERAL DESCRIPTION
GD(H6DO)-206

GENERAL DESCRIPTION
ER:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

(3) (4)
(1)
(2)
EN-01859
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H6DO)-207

GENERAL DESCRIPTION
Map
GD(H6DO)-208

GENERAL DESCRIPTION
ES:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

(4) (1)
(2)
(3)
EN-01861
(1) (2)
(3)
(4)
3. ENABLE CONDITION

GD(H6DO)-209

GENERAL DESCRIPTION
Map
Throttle position sensor 1 opening angle () = d Sensor output difference () 0 d d < 0.6 1.465 0.6 d d < 1.2 1.597 1.2 d d < 2 1.663 2dd<4 2.455 4dd 3.116
GD(H6DO)-210

GENERAL DESCRIPTION
ET:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE

Detect the malfunction of barometric pressure sensor output property. Judge as NG when the barometric pressure sensor output is largely different from the intake manifold pressure at engine start.
3. ENABLE CONDITION
Secondary Parameters Engine speed Vehicle speed Enable Conditions < 300 rpm < 1 km/h (0.6 MPH)

Perform the diagnosis once at ignition switch ON.
Malfunction criteria |Barometric pressure Intake manifold pressure| |Intake manifold pressure at engine start Intake manifold pressure| Threshold value t 26.7 kPa (200 mmHg, 7.9 inHg) < 1.3 kPa (9.99 mmHg, 0.4 inHg)
Malfunction criteria |Barometric pressure Intake manifold pressure| Threshold value < 26.7 kPa (200 mmHg, 7.9 inHg)
GD(H6DO)-211

GENERAL DESCRIPTION
EU:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW

3. ENABLE CONDITION

GD(H6DO)-212

GENERAL DESCRIPTION
EV:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH

3. ENABLE CONDITION

GD(H6DO)-213

GENERAL DESCRIPTION
GD(H6DO)-214
General Description
CONTROL SYSTEMS
A: SPECIFICATION
Item Swing torque of rod against lever N (kgf, lb) Specification 3.7(0.38, 0.83) or less
CS-2
General Description
CONTROL SYSTEMS
B: COMPONENT
1. AT SELECT LEVER
(1) (20) (21)
(19) (2)
(22)
(23) T1 (4) (3) (5)

P R N D
(24) (26) (27) (24) (6) (25) T4 (29) (31) (17) (28) (8) (7)
T1 (10) (11) T2 (9)
(30) T5 (35) (36) (32) (34) (16) (38)
(13) (12)
(15) (14) (18)
(40)
(37) (33) (39) T3 CS-00685
CS-3
General Description
CONTROL SYSTEMS
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) Ring indicator Front cover Grip Release cover Indicator ASSY Indicator bulb Valve harness Blind Detent spring Spring washer Washer Guide plate upper Up switch Down switch SPORT mode switch Switch cover (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) Shift lock solenoid ASSY Check plate Lever ASSY Check ball Return spring Shaft Washer Bushing A Arm ASSY Bushing plate Bushing B Shaft Plate lower Clamp Collar Gasket (33) (34) (35) (36) (37) (38) (39) (40) Cable bracket Seat Washer Snap pin Select cable Clamp Nut A Bushing
Tightening torque:Nm (kgf-m, ft-lb) T1: 5.1 (0.5, 3.8) T2: 6.9 (0.7, 5.1) T3: 7.5 (0.8, 5.5) T4: 12.7 (1.3, 9.4) T5: 18 (1.8, 13.3)
CS-4
General Description
CONTROL SYSTEMS
2. 5MT GEAR SHIFT LEVER

(1)
(2) (3)
T1 (16) (26) (4) (17) (7) (19) (24) T2 (7) (26) (18) (26) (7) (7) (7) (19) (8) (9) (12) (10) (11) (13) (14) (20) (15) (25) (21) T2 (5) T1 T2 (6) (7) (3)
(19)
T2 (26)
(22) T2
(23)
CS-00267
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Gear shift knob Front cover ASSY Clamp Boot and insulator ASSY Plate ASSY Lever Bushing Lock wire Snap ring Bushing
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
O-ring Spring pin Bushing B O-ring Boot Spring pin Joint Rod Spacer Bracket
(21) (22) (23) (24) (25) (26)
Washer Stay Cushion rubber Boss Bushing Self-locking nut
CS-5
General Description
CONTROL SYSTEMS
3. 6MT GEAR SHIFT LEVER
(1)
(2) (29) T2 (6) (36) (28) (12) (13) (13) (33) (12) (12) (12) T2 (12) (14) (15) (16) (34) T1 (13) (11) (12) (30) (32) T2 (7) (8) (9) (36) T3 (4) (3) (3)
(10) (37)
(5)
(17) (18)
(35)
(19) (31)
(26) (23) (21) (27) (24) (25)
T4
(22)
(20)
T3
CS-00967
CS-6
General Description
CONTROL SYSTEMS
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) Gear shift knob Front cover ASSY Clamp Boot and insulator ASSY Plate ASSY Slider Spring pin Spring Holder Seat cushion Lever Bushing Spacer Lock wire Snap ring (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) Bushing Spring pin Bushing Boot Stay Cushion rubber Bushing Reverse check cable Washer Snap pin Bracket Cable plate Joint Spring pin (30) (31) (32) (33) (34) (35) (36) (37) Rod Reverse check lever Band clip Boss O-ring O-ring Screw Spring seat
CS-7
General Description
CONTROL SYSTEMS
C: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
D: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Use SUBARU genuine fluid, grease etc. or equivalent. Do not mix fluid, grease, etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Apply grease onto sliding or revolving surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation. Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise. Before disconnecting electrical connectors, be sure to disconnect the negative terminal from battery.
CS-8
AT Shift Lock Control System

CONTROL SYSTEMS
2. AT Shift Lock Control System

A: LOCATION
(4)
(7)
(6)
(1) (3) (2) (5)
CS-00513
(1) (2) (3)
TCM (P range) Body integrated unit Stop light switch
(4) (5)
Key cylinder (with built-in key warning switch) Shift lock solenoid ASSY
(6) (7)
P range switch Key lock solenoid
CS-9

CONTROL SYSTEMS
(1) (2) CS-00835 CS-00743
(3)
(7)
(4)
CS-00270 (6)
CS-00359
(5) CS-00543
CS-10

CONTROL SYSTEMS
B: ELECTRICAL SPECIFICATION
TO
A:
i84
TO
B: B281
TO
C: B280
8 7 6 5 4 3 2 1 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 35 34 33 32 31 30 29 28 27 26 25 24
7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 28 27 26 25 24 23 22 21 20
7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 30 29 28 27 26 25 24 23 22 21
SL-00692
Item Battery power supply Ignition power supply TCM (P range) Stop light switch P range switch Shift lock solenoid signal Key warning switch signal Key lock solenoid signal
Connector No. B281 i84 i84 B280 B280 B281 B281 B280 B281 B280 B280 i84 B281
Terminal No. 1 2 1 24 20 30 23 13 6 7 5 22 21 8 9
Input/Output signal Measured value and measuring conditions 9 16 V 10 15 V when ignition switch is at ON or START. 10 15 V when ignition switch is at ACC. Pulse signal 9 16 V when stop light switch is ON. 0 V when stop light switch is OFF. 0 V when select lever is in P range. 9 16 V when select lever is in other ranges than P range. 8.5 16 V when shift lock is released. 0 V when shift lock is operating. 9 16 V when key is inserted. 0 V when key is removed. 7.5 16 V when ignition switch is turned ON, with select lever in P range and brake switch ON. 0 V at other conditions than above.
Ground
CS-11

CONTROL SYSTEMS
C: WIRING DIAGRAM
(10)
(1)
OFF ACC ON
(5)
(2) (6)
(4) (7)
(3)
(8)
(9)
CS-00909
(1) (2) (3) (4)
Ignition switch Stop light switch Key warning switch Body integrated unit
(5) (6) (7)
TCM (shift range information) Key lock solenoid Shift lock solenoid
(8) (9) (10)
P range switch Battery VDC/ABS (vehicle speed signal)
CS-12

CONTROL SYSTEMS
D: INSPECTION
1. SHIFT LOCK OPERATION
1 Step Check Yes CHECK COMMUNICATION OF SUBARU SE- Is the system name displayed? Go to step 2. LECT MONITOR. 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to all systems can be executed normally. No Perform the inspection following the diagnostic procedure in the LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.> Go to step 3.
CHECK SHIFT LOCK. 1) Turn the ignition switch to ON. 2) Shift the select lever to the P range.
While brake pedal is not depressed, is it possible to move the select lever from the P range to other ranges?
CHECK SHIFT LOCK.
While brake pedal is depressed, is it possible to move the select lever from the P range to other ranges?
Perform the inspection of SELECT LEVER CANNOT BE LOCKED OR RELEASED. <Ref. to CS-17, SELECT LEVER CANNOT BE LOCKED OR RELEASED, INSPECTION, AT Shift Lock Control System.> Go to step 4.
CHECK SHIFT LOCK. Shift the select lever to N range.
Is it possible to move the select Go to step 5. lever from the N range to the P range?
Perform the inspection of SELECT LEVER CANNOT BE LOCKED OR RELEASED. <Ref. to CS-17, SELECT LEVER CANNOT BE LOCKED OR RELEASED, INSPECTION, AT Shift Lock Control System.> Perform the inspection of SELECT LEVER CANNOT BE LOCKED OR RELEASED. <Ref. to CS-17, SELECT LEVER CANNOT BE LOCKED OR RELEASED, INSPECTION, AT Shift Lock Control System.>
CS-13

CONTROL SYSTEMS
Step CHECK SHIFT LOCK. 1) Shift the select lever to N range. 2) Turn the ignition switch to OFF. Check While brake pedal is depressed, is it possible to move the select lever from the N range to the P range? Yes Go to step 6. No Perform the inspection of SELECT LEVER CANNOT BE LOCKED OR RELEASED. <Ref. to CS-17, SELECT LEVER CANNOT BE LOCKED OR RELEASED, INSPECTION, AT Shift Lock Control System.> Go to step 7.
CHECK KEY INTERLOCK. Can the ignition key be 1) Turn the ignition switch to OFF. removed? 2) Shift the select lever to other than P range.
CHECK KEY INTERLOCK. Shift the select lever to the P range.
Can the ignition key be removed?
Perform the inspection of KEY INTERLOCK CANNOT BE LOCKED OR RELEASED. <Ref. to CS-20, KEY INTERLOCK CANNOT BE LOCKED OR RELEASED, INSPECTION, AT Shift Lock Control System.> AT shift lock sys- Perform the tem is normal. inspection of KEY INTERLOCK CANNOT BE LOCKED OR RELEASED. <Ref. to CS-20, KEY INTERLOCK CANNOT BE LOCKED OR RELEASED, INSPECTION, AT Shift Lock Control System.>
CS-14

CONTROL SYSTEMS
2. BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT

IGNITION SWITCH OFF ACC ON B ACC IG SBF-8 SBF-6 MAIN SBF
A21
A24
B22
A1
C2
C8
A:
i84 BODY INTEGRATED UNIT
B: B280 C: B281
C1
C9
BATTERY
No. 12
No. 31
No. 14
No. 7
A:
i84
B: B280
C: B281
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
4 5 6 7 1 2 3 8 9 10 11 12 13 14 15 16 17 18 19 27 28 22 23 24 25 26 20 21
CS-00982
CS-15

CONTROL SYSTEMS
Step CHECK DTC OF BODY INTEGRATED UNIT. Check DTC of the body integrated unit. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND CHASSIS GROUND. 1) Turn the ignition switch to ON. 2) Measure the voltage between the body integrated unit and chassis ground. Connector & terminal (B281) No. 2 (+) Chassis ground (): (B281) No. 1 (+) Chassis ground (): (i84) No. 1 (+) Chassis ground (): (i84) No. 24 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Measure the resistance of the harness between the body integrated unit and chassis ground. Connector & terminal (i84) No. 21 Chassis ground: (B280) No. 22 Chassis ground: (B281) No. 8 Chassis ground: (B281) No. 9 Chassis ground: CHECK POOR CONTACT. Check Yes No Is the DTC of power line disRepair or replace it Go to step 2. played on body integrated unit? according to the DTC. Is the voltage 9 16 V? Go to step 3. Repair harness for open circuit between the body integrated unit and the battery or a blown fuse.
Repair the open circuit of harness between the body integrated unit and chassis ground.
Is there poor contact in connec- Repair the poor tor? contact.
Check the body integrated unit.
CS-16

CONTROL SYSTEMS
3. SELECT LEVER CANNOT BE LOCKED OR RELEASED

BATTERY No. 8 SBF-2 MAIN SBF
No. 14
STOP LIGHT SWITCH 2 3 B65
KEY WARNING SWITCH FUSE B225 (RELAY BLOCK) 7.5A 4 C23 3
3 4 B350 C7 C1
FUSE & RELAY BOX F9 F5 F : B159
B: B280 BODY INTEGRATED UNIT C: B281 4AT : 4 SPEED AT B20 B30 B6 5AT : 5 SPEED AT
P RANGE SWITCH B21 A18 B20 A17 5AT 4AT
C13
SHIFT LOCK SOLENOID 1 2 3 4 B116
B116
A: B54
B: TCM
B55
B65
B116
F : B159
B: B280
C: B281
1 3
2 4
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
4 5 6 7 1 2 3 8 9 10 11 12 13 14 15 16 17 18 19 27 28 22 23 24 25 26 20 21
A:
B54
: 4AT 5 6 14 15 16 25 26 27 33 34 35
B:
B55
: 5AT
1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28
B225
13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CS-00965
CS-17

CONTROL SYSTEMS
Step CHECK BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT. <Ref. to CS-15, BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT, INSPECTION, AT Shift Lock Control System.> CHECK CURRENT DATA. 1) Connect the Subaru Select Monitor. 2) Shift the select lever to the P range. 3) Turn the ignition switch to ON. 4) Display the current data display and display P SW. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK CURRENT DATA. Display the current data display and display Stop Light Switch. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT DTC. Check the DTC of the body integrated unit when the brake pedal is pressed and when it is released. (Hold each condition for 5 seconds or more.) CHECK CURRENT DATA. Select the current data display and display Shift Lock Solenoid. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK CURRENT DATA. Select the current data display and display Shift Position. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> Check Yes Is there an abnormal condition? Follow the procedures to perform inspection and repair. Is the display ON in the P range and OFF in ranges other than P? Go to step 3. No Go to step 2.
Go to step 8.
Go to step 4. Go to step 11. Is ON displayed when the brake pedal is depressed and OFF displayed when the brake pedal is released? Is there a DTC of a current mal- Follow the DTC to Go to step 5. function? perform inspection and repair.
Is ON displayed when the Go to step 6. brake pedal is depressed and OFF displayed when the brake pedal is released? Is the display 7 in the P range Go to step 7. and other than 7 in ranges other than P?
Replace the body integrated unit.
CHECK CURRENT DATA. Is a figure equivalent to the Go to step 12. 1) Select the current data display and display speedometer being indicated? Front Wheel Speed. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> 2) Start the engine. 3) Raise vehicle speed gradually up to approximately 20 km/h.
Check the following items. Inhibitor switch Harness between inhibitor switch and TCM TCM input signal TCM CAN communication Body integrated unit CAN receive Check the following items. Wheel speed sensor VDC/ABS CAN communication Body integrated unit CAN receive Replace the wheel speed sensor, VDC/ABS, or body integrated unit, or both.
CS-18

CONTROL SYSTEMS
Step CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND P RANGE SWITCH. 1) Disconnect the connector from body integrated unit. 2) Disconnect the connector of P range switch. 3) Check for open circuit of harness, short circuit to battery or short circuit to ground between the body integrated unit and P range switch. Connector & terminal (B281) No. 13 (B116) No. 1: CHECK HARNESS BETWEEN P RANGE SWITCH AND CHASSIS GROUND. Measure the resistance of harness between P range switch and chassis ground. Connector & terminal (B116) No. 2 Chassis ground: CHECK P RANGE SWITCH. Measure the resistance between P range switch connector terminals. Terminals No. 2 No. 1: CHECK STOP LIGHT SWITCH INPUT SIGNAL. 1) Disconnect the connector from body integrated unit. 2) Measure the voltage between the body integrated unit connector terminal and chassis ground. Connector & terminal (B281) No. 23 (+) Chassis ground (): CHECK SHIFT LOCK SOLENOID OPERATION. Connect the battery to the shift lock solenoid unit connector terminal, and operate the solenoid. Terminals No. 3 (+) No. 4 (): Check Is the harness normal? Yes Go to step 9. No Repair or replace the harness between the body integrated unit and the P range switch.
Is it less than 10 :?
Go to step 10.
Repair the harness between the P range switch and chassis ground.
10
Is it less than 10 : in the P range, and 1 M: or more in ranges other than P?
Replace the P range switch.
11
Is the voltage 9 V or more when Replace the body the brake pedal is depressed, integrated unit. and less than approximately 1.5 V when not pressed?
Check the stop light system.
12
Does the shift lock solenoid operate normally?
Check the lock Replace the shift mechanism of the lock solenoid. select lever body.
CS-19

CONTROL SYSTEMS
4. KEY INTERLOCK CANNOT BE LOCKED OR RELEASED

SBF-8
No. 14
No. 7
KEY WARNING SWITCH
3 4 B350 C1 C2 C7
A:
i84 BODY INTEGRATED UNIT
B: B280 C: B281 C13 A3
P RANGE SWITCH
i3 1 2 2 B116 DELIVERY (TEST) MODE CONNECTOR 2 7 B38 B350 1 B75 B76 2
KEY LOCK SOLENOID
B75 1 2
B5
B76 1 2
B350
B116
B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B:
B280
1 2 3 4
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
C:
B281
A:
i84
4 5 6 7 1 2 3 8 9 10 11 12 13 14 15 16 17 18 19 27 28 22 23 24 25 26 20 21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
BATTERY
CS-00981
CS-20

CONTROL SYSTEMS
Step CHECK DELIVERY (TEST) MODE CONNECTOR. Check that the delivery (test) mode connector is disconnected. CHECK BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT. <Ref. to CS-15, BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT, INSPECTION, AT Shift Lock Control System.> CHECK CURRENT DATA. 1) Connect the Subaru Select Monitor. 2) Shift the select lever to the P range. 3) Turn the ignition switch to ON. 4) Display the current data display and display P SW. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK CURRENT DATA. 1) Select the current data display and display the Key-lock warning SW. <Ref. to LAN(diag)12, OPERATION, Subaru Select Monitor.> 2) Turn the ignition switch to OFF. CHECK CURRENT DATA. 1) Turn the ignition switch to ON. 2) Select the current data display and display Key locking output. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK DTC OF BODY INTEGRATED UNIT. 1) Set the select lever to a range other than the P range. 2) Check DTC of body integrated unit. CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND P RANGE SWITCH. 1) Disconnect the connector from body integrated unit. 2) Disconnect the connector of P range switch. 3) Check for open circuit of harness, short circuit to battery or short circuit to ground between the body integrated unit and P range switch. Connector & terminal (B281) No. 13 (B116) No. 1: CHECK HARNESS BETWEEN P RANGE SWITCH AND CHASSIS GROUND. Measure the resistance of harness between P range switch and chassis ground. Connector & terminal (B116) No. 2 Chassis ground: CHECK P RANGE SWITCH. Measure the resistance between P range switch connector terminals. Terminals No. 2 No. 1: Check Yes Is the delivery (test) mode con- Go to step 2. nector disconnected? No Disconnect the delivery (test) mode connector. Go to step 3.
Is there an abnormal condition? Follow the procedures to inspect and repair.
Is the display ON in the P range and OFF in ranges other than P?
Go to step 4.
Go to step 7.
Does the display change from ON to OFF when the key is inserted and removed?
Go to step 5.
Go to step 10.
Is the display ON in the P range and OFF in ranges other than P?
Go to step 12.
Go to step 6.
Is B1105 (key interlock circuit Follow the DTC to Go to step 11. malfunction) a current malfunc- perform inspection tion? and repair. Is the harness normal? Go to step 8. Repair or replace the harness between the body integrated unit and the P range switch.
Go to step 9.
Repair the harness between the P range switch and chassis ground.
Is it less than 10 : in the P range, and 1 M: or more in ranges other than P?
CS-21

CONTROL SYSTEMS
Step CHECK HARNESS BETWEEN BATTERY AND KEY WARNING SWITCH AND BODY INTEGRATED UNIT. 1) Disconnect the connector from body integrated unit. 2) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B281) No. 7 Chassis ground: CHECK DELIVERY (TEST) MODE CONNECTOR HARNESS. 1) Disconnect the connector of body integrated unit. 2) Check for open circuit of harness, short circuit to battery or short circuit to ground between the body integrated unit connector and delivery (test) mode connector. Connector & terminal (i84) No. 3 (i3) No. 7: CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND KEY LOCK SOLENOID. 1) Disconnect the connector from body integrated unit. 2) Disconnect the connector from the key lock solenoid. 3) Check for open circuit of harness, short circuit to battery or short circuit to ground between the body integrated unit and key lock solenoid. Connector & terminal (B280) No. 5 (B350) No. 2: CHECK HARNESS BETWEEN KEY LOCK SOLENOID AND CHASSIS GROUND. Measure the resistance of harness between key lock solenoid and chassis ground. Connector & terminal (B350) No. 1 Chassis ground: CHECK KEY LOCK SOLENOID OPERATION. Connect the battery to the key lock solenoid connector terminal, and operate the solenoid. CHECK OUTPUT OF BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Insert the key. 3) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B280) No. 5 Chassis ground: Check Yes Is the display 9 V or more when Replace the body integrated unit. the key is inserted, and less than 1.5 V with the key removed? No Check the following items. Key warning switch Harness/fuse Ignition circuit
10
11
Is the harness normal?
Go to step 12.
Repair or replace the harness between the body integrated unit and delivery (test) mode connector.
12
Is the harness normal?
Go to step 13.
Repair or replace the harness between the body integrated unit and the key lock solenoid.
13
Go to step 14.
Repair or replace the harness between the key lock solenoid and chassis ground. Replace the key lock solenoid.
14
Does the key lock solenoid operate normally?
Go to step 15.
15
Is it 5 V or more in ranges other Check the lock Replace the body than P, and less than 1.5 V in mechanism of the integrated unit. the P range? steering lock body.
CS-22
Select Lever
CONTROL SYSTEMS
3. Select Lever
A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from the battery. 3) Shift the select lever to N range. 4) Lift up the vehicle. 5) Remove the rear exhaust pipe and muffler. SOHC model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> DOHC turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> DOHC 3.0 L model <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 6) Remove the heat shield cover.
8) Raise the claw of clamp to remove the cable.
(A) CS-00279
(A) Claw
9) Lower the vehicle. 10) Remove the console box. <Ref. to EI-54, REMOVAL, Console Box.> 11) Remove the center console. <Ref. to EI-55, REMOVAL, Center Console.> 12) Remove the harness clips from the bracket.
AT-01331
CS-00518
7) Remove the cable from the arm assembly.
13) Disconnect the connectors, and then remove the four bolts to take out the select lever assembly from vehicle body.
(B)
(A)
CS-00278 CS-00519
(A) Adjusting nut (B) Arm ASSY
CS-23
Select Lever
CONTROL SYSTEMS
B: INSTALLATION
1) Set the select lever to vehicle body. 2) Tighten the four bolts to install the select lever to vehicle body, and then connect the connector. (1) Temporarily tighten the bolt A. (2) Tighten the bolt B. (3) Tighten the bolt A. (4) Tighten the bolts C and D. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
C B
13) Install the rear exhaust pipe and muffler. SOHC model <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> DOHC turbo model <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> DOHC 3.0 L model <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, INSTALLATION, Muffler.> 14) Inspect the following items. When a malfunction is found in the inspection, adjust the select cable and inhibitor switch. <Ref. to CS-32, ADJUSTMENT, Select Cable.> <Ref. to 4AT-46, ADJUSTMENT, Inhibitor Switch.> NOTE: Inhibitor switch for 5AT model is not adjustable. (1) Engine starts when the select lever is in P and N range, but not in other ranges. (2) Back-up light illuminates when the select lever is in the R range, but not in other ranges. (3) Select lever and indicator positions are matched.
D CS-00520
3) Install the harness clips to the bracket.
CS-00518
4) Install the center console. <Ref. to EI-56, INSTALLATION, Center Console.> 5) Install the console box. <Ref. to EI-54, INSTALLATION, Console Box.> 6) Shift the select lever to N range. 7) Lift up the vehicle. 8) Shift the range select lever to the N range. 9) Secure the cable to the bracket. <Ref. to CS-30, INSTALLATION, Select Cable.> 10) Adjust the select cable position. <Ref. to CS32, ADJUSTMENT, Select Cable.> 11) After the completion of adjustment, confirm that the select lever operates properly at all range positions. 12) Install the heat shield cover.
CS-24
Select Lever
CONTROL SYSTEMS
C: DISASSEMBLY
1) Shift the select lever to N range. 2) Remove the indicator bulb.
7) Remove the bolt, and separate the guide plate upper from plate lower.
(B) (A)
CS-00524 CS-00521
3) Remove the grip. 4) Remove the indicator assembly.
(A) Guide plate upper (B) Plate lower
8) Remove the connector from the guide plate upper.
CS-00522
5) Remove the blind.
CS-00525
9) Remove the sheet, and remove the shift lock solenoid assembly.
CS-00523
6) Shift the select lever to the N range, and then remove the detent spring. 10) Remove the switch assembly.
CS-00526
CS-00538 CS-00527
CS-25
Select Lever
CONTROL SYSTEMS
11) Remove the check plate.
15) Remove the gasket.
CS-00528
CS-00531
12) Raise the claw of connector.
16) Remove the select lever assembly.
CS-00292
CS-00532
13) Disconnect the terminals of the SPORT mode switch and shift lock solenoid assembly from the connector, using a flat tip screwdriver with a thin tip.
17) Remove the clamp, and remove the arm assembly and bushing plate.
(A) (B) (D) (C)
(A) 4 3 2 1 10 9 8 7 6 5
(C)
CS-00686 CS-00529
(A) P range switch
14) Remove the cable bracket.
(A) (B) (C) (D)
Arm ASSY Bushing plate Bushing A Bushing B
CS-00530
CS-26
Select Lever
CONTROL SYSTEMS
D: ASSEMBLY
1) Clean all the parts before assembly. 2) Apply NIGTIGHT LYW No. 2 grease or the equivalent to each part. <Ref. to CS-3, AT SELECT LEVER, COMPONENT, General Description.> 3) Assemble in the reverse order of disassembly. NOTE: Refer to COMPONENT for each tightening torque. <Ref. to CS-3, AT SELECT LEVER, COMPONENT, General Description.> Connect the switch terminal to the connector.
(A) 4 3 2 1 10 9 8 7 6 5
CS-00529
(A) P range switch
4) After completing installation, shift the select lever from P range to D range, then check whether the indicator and select lever matches, whether the pointer and position mark matches and what the operating force is.
E: INSPECTION
1) Inspect the removed parts by comparing with new parts for deformation, damage and wear. Repair or replace if defective. 2) Confirm the select lever operating condition before assembly. Normal if it operates smoothly.
CS-27
Select Cable
CONTROL SYSTEMS
4. Select Cable
A: REMOVAL
1) Set the vehicle on a lift. 2) Shift the select lever to N range. 3) Disconnect the ground cable from the battery. 4) Lift up the vehicle. 5) Remove the front, center and rear exhaust pipes and the muffler. (Non-turbo model) SOHC model <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> DOHC 3.0 L model <Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 6) Remove the center and rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)14, REMOVAL, Muffler.> 7) Remove the heat shield cover.
8) Remove the snap pin and washer from the shifter arm. (4AT model)
(E) (B)
(D)
(C)
(A) CS-00954
(A) (B) (C) (D) (E)
Shifter arm Snap pin Select cable Bracket Washer
9) Remove the snap pin and washer from the range select lever. (5AT model)
(B) (E)
(D) (A)
(C)
CS-00327
(A) Range select lever (B) Snap pin (C) Select cable (D) Bracket (E) Washer
AT-01331
CS-28
Select Cable
CONTROL SYSTEMS
10) Remove the plate assembly from the transmission case. 4AT
12) Raise the claw of clamp to remove the cable from bracket.
(A) (B) (A) CS-00955 CS-00279
(A) Claw (A) Select cable (B) Plate ASSY
13) Remove the select cable from plate assembly.
5AT
(A)
(B) CS-00328
(A) Select cable (B) Plate ASSY
11) Disconnect the cable from the arm assembly.
(B)
(A)
CS-00278
(A) Adjusting nut (B) Arm ASSY
CS-29
Select Cable
CONTROL SYSTEMS
B: INSTALLATION
1) Install the select cable to the plate assembly. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
5) Install the washer and snap pin to the shifter arm. (4AT model)
(E)
T
(B)
(D)
(C)
(A) CS-00954
CS-00607
2) Install the select cable to the shifter arm. (4AT model) 3) Install the select cable to the range select lever. (5AT model) 4) Install the plate assembly to the transmission. Tightening torque: T: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 4AT
T
(A)
(A) (B) (C) (D) (E)
Shifter arm Snap pin Select cable Bracket Washer
6) Install the washer and snap pin to the range select lever. (5AT model)
(B) (E)
(D) (A)
(C)
CS-00327 (B) CS-00956
(A) Range select lever (B) Snap pin (C) Select lever (D) Bracket (E) Washer
5AT
(A)
7) Install new clamp paying attention to the installing direction.
C (A) C (B) CS-00328 (B) CS-00329
(A) Clamp (B) Forward
CS-30
Select Cable
CONTROL SYSTEMS
8) Insert the tip of inner cable into connector hole of select lever, and fix the cable to bracket.
C: INSPECTION
Check the removed cable and replace or adjust if damaged, rusty or malfunctioning. 1) Check the cable for smooth operation. 2) Check the inner cable for damage and rust. 3) Check the outer cable for damage, bends and cracks. 4) Check the boot for damage, cracks and deterioration. 5) Move the select lever from P to D range. Check the existence of feel to contact the detents in each range. If the detents cannot be felt or the position pointer is improperly aligned, adjust the cable. 6) Check if the starter motor rotates when the select lever is set to P range. 7) Check the back-up light illumination when the select lever is in R range. 8) Check the parking lock operation when the select lever is in P range.
CS-00330
9) Shift the select lever to the N range, and then adjust the select cable position. <Ref. to CS-32, ADJUSTMENT, Select Cable.> 10) Install the heat shield cover.
AT-01331
11) Install the front, center and rear exhaust pipes, and the muffler. (Non-turbo model) SOHC model <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4SO)8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> DOHC 3.0 L model <Ref. to EX(H6DO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, INSTALLATION, Muffler.> 12) Install the center, rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.>
CS-31
Select Cable
CONTROL SYSTEMS
D: ADJUSTMENT
1) Set the vehicle on a lift. 2) Shift the select lever to N range. 3) Lift up the vehicle. 4) Remove the rear exhaust pipe and muffler. SOHC model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> DOHC turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> DOHC 3.0 L model <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 5) Remove the heat shield cover.
7) Turn adjusting nut B until it lightly touches the connector.

(B)
(A)
(C)
(D) (E)
(F) CS-00041
(A) (B) (C) (D) (E) (F)
Forward side Select lever Connector Adjusting nut B Contact point Adjusting nut A
8) Set a spanner wrench to adjusting nut B so that it does not rotate, and then tighten the adjusting nut A. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
AT-01331
6) Loosen the adjusting nuts on both sides.
(B)
(A)
CS-00042
(B)
(A) CS-00040
(A) Adjusting nut A (B) Adjusting nut B
(A) Adjusting nut A (B) Adjusting nut B
9) After the completion of adjustment, confirm that the select lever operates normally at all ranges. 10) Install in the reverse order of removal.
CS-32
Paddle Shift Assembly

CONTROL SYSTEMS
5. Paddle Shift Assembly

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Set the tire to the straight-ahead position. 3) Remove the airbag module. <Ref. to AB-14, REMOVAL, Drivers Airbag Module.> WARNING: If there are airbag modules mounted, always refer to Airbag System when performing airbag module service. <Ref. to AB-4, CAUTION, General Description.> 4) Remove the steering wheel. <Ref. to PS-13, REMOVAL, Steering Wheel.> 5) Remove the column cover. 6) Disconnect the connector of paddle shift assembly.
B: INSTALLATION
1) Clean all parts before installation. 2) Install in the reverse order of removal. 3) After completing installation, shift the select lever to the manual mode. 4) Operate the paddle shift assembly and confirm that 2 illuminates on the combination meter.
CS-00728
7) Remove the paddle shift assembly.
CS-00838
CS-33
Paddle Shift Assembly

CONTROL SYSTEMS
C: INSPECTION
3 2 1
CS-00730
Step Check SHIFT-UP SWITCH CONTINUITY CHECK. Is the resistance less than 10 :? 1) Operate the + side of paddle shift assembly and hold it. 2) Measure the resistance between the paddle shift assembly connector terminals. Terminals No. 1 No. 2: SHIFT-DOWN SWITCH CONTINUITY Is the resistance less than 10 :? CHECK. 1) Operate the side of paddle shift assembly and hold it. 2) Measure the resistance between the paddle shift assembly connector terminals. Terminals No. 3 No. 2: CHECK SHIFT SWITCH INSULATION. Is the resistance 1 M:? 1) Do not operate the paddle shift assembly. 2) Measure the resistance between the paddle shift assembly connector terminals. Terminals No. 2 No. 1: No. 2 No. 3:
Yes Go to step 2.
No Replace the paddle shift assembly.
Go to step 3.
Replace the paddle shift assembly.
Paddle shift assembly is normal.
Replace the paddle shift assembly.
CS-34
AT Shift Lock Solenoid and P Range Switch

CONTROL SYSTEMS
6. AT Shift Lock Solenoid and P Range Switch

A: REMOVAL
1) Remove the console box. <Ref. to EI-54, REMOVAL, Console Box.> 2) Disconnect the connector. 3) Remove the indicator bulb.
7) Shift the select lever to the N range, and then remove the detent spring.
CS-00538
8) Remove the switch assembly and shift lock solenoid assembly.
CS-00521
4) Remove the grip. 5) Remove the indicator cover.
CS-00536
9) Remove the bolts, then remove the guide plate upper from the plate lower.
CS-00522
(B) (A)
6) Disconnect the connector from the guide plate upper.
CS-00524
(A) Guide plate upper (B) Plate lower
10) Raise the claw of the connector.

CS-00525
CS-00292
CS-35

CONTROL SYSTEMS
11) Disconnect the terminal of the P range switch from connector, using a flat tip screwdriver with a thin tip.
(A) 4 3 2 1 10 9 8 7 6 5
CS-00529
(A) P range switch
B: INSTALLATION
Install in the reverse order of removal. NOTE: Refer to COMPONENT for each tightening torque. <Ref. to CS-3, AT SELECT LEVER, COMPONENT, General Description.> Connect the P range switch terminal to connector.
(A) 4 3 2 1 10 9 8 7 6 5
CS-00529
(A) P range switch
CS-36

CONTROL SYSTEMS
C: INSPECTION
1 Step CHECK SHIFT LOCK SOLENOID. Measure the resistance of shift lock solenoid connector terminals. Terminals No. 4 No. 3: CHECK SHIFT LOCK SOLENOID. Connect the battery to shift lock solenoid connector terminal, and then operate the solenoid. Terminals No. 3 (+) No. 4 (): CHECK P RANGE SWITCH. 1) Move the select lever to P range. 2) Measure the resistance between P range switch connector terminals. Terminals No. 1 No. 2: CHECK P RANGE SWITCH. 1) Set the select lever to a range other than the P range. 2) Measure the resistance between P range switch connector terminals. Terminals No. 1 No. 2: Check Yes Is the resistance 19.8 24.2 :? Go to step 2. No Replace the shift lock solenoid.
Does the shift lock solenoid operate normally?
Go to step 3.
Replace the shift lock solenoid.
Normal operation
CS-37
Body Integrated Unit

CONTROL SYSTEMS
7. Body Integrated Unit

A: NOTE
Refer to Body Integrated Unit for removal and installation procedure. <Ref. to SL-56, Body Integrated Unit.>
CS-38
MT Gear Shift Lever

CONTROL SYSTEMS
8. MT Gear Shift Lever

A: REMOVAL
1. 5MT MODEL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from the battery. 3) Remove the gear shift knob. 4) Remove the console box. <Ref. to EI-54, REMOVAL, Console Box.> 5) Remove the front cover assembly. 6) Remove the clamp.
9) Remove the plate assembly from the vehicle body.
CS-00563
CS-00311
7) Remove the bushing and insulator assembly.
10) Lift up the vehicle. 11) Remove the rear exhaust pipe and muffler. SOHC model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> DOHC turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 12) Remove the heat shield cover.
CS-00312
AT-01331
8) Remove the harness clamp from the plate assembly.
13) Remove the stay from transmission bracket.
(A)
(B) CS-00050 CS-00313
(A) Stay (B) Transmission bracket
CS-39
MT Gear Shift Lever

CONTROL SYSTEMS
14) Remove the rod from joint.
18) Remove the gear shift lever.
(A) (B)
CS-00051
CS-00315
(A) Stay (B) Rod
2. 6MT MODEL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from the battery. 3) Remove the gear shift knob. 4) Remove the console box front. <Ref. to EI-54, REMOVAL, Console Box.> 5) Remove the front cover assembly. 6) Remove the clamp.
15) Remove the cushion rubber from the vehicle body.
(A)
(B)
CS-00052
(A) Stay (B) Cushion rubber
CS-00311
16) Extract the spring pin and remove the joint.

(A)
7) Remove the bushing and insulator assembly.
(B)
CS-00053
CS-00312
(A) Joint (B) Spring pin
8) Remove the harness clamp from the plate assembly.
CS-00581
CS-40
MT Gear Shift Lever

CONTROL SYSTEMS
9) Remove the plate assembly from the vehicle body.
16) Move the transmission to the right side, and remove the joint COMPL, stay bolts and reverse check cable. NOTE: If the transmission is not moved aside, the joint COMPL and stay bolts may contact the body and cause damage.
(C) (A)
CS-00584
(B)
10) Lift up the vehicle. 11) Remove the under cover. 12) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 13) Remove the heat shield cover.
CS-00221
(A) Joint COMPL bolt (B) Stay bolt (C) Reverse check cable
17) Remove the cushion rubber from the vehicle body.
AT-01331
14) Remove the crossmember. <Ref. to 6MT-30, REMOVAL, Transmission Mounting System.> 15) Remove the snap pin and washer, and remove the reverse check cable from the reverse check lever.
CS-00222
18) Lower the vehicle. 19) Remove the gear shift lever.
(A)
(B)
(C) CS-00220
(A) Snap pin (B) Washer (C) Reverse check cable
CS-41
MT Gear Shift Lever

CONTROL SYSTEMS
B: INSTALLATION
1. 5MT MODEL
1) Install the joint to the transmission and secure with a spring pin.
(A)
5) Using new self-locking nuts, connect the rod to the joint. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A) (B)
(B) CS-00051 CS-00053
(A) Joint (B) Spring pin
(A) Stay (B) Rod
2) Insert the gear shift lever from the room side. NOTE: Insert the rod and the stay, and then temporarily set them onto the transmission mount.
6) Using new self-locking nuts, connect the stay to the transmission bracket. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A)
(B) CS-00315 CS-00050
3) Lift up the vehicle. 4) Mount the cushion rubber on the vehicle body. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A) Stay (B) Transmission bracket
7) Install the heat shield cover.
(A)
(B)
AT-01331 CS-00052
(A) Stay (B) Cushion rubber
CS-42
MT Gear Shift Lever

CONTROL SYSTEMS
8) Install the rear exhaust pipe and muffler. SOHC model <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> DOHC turbo model <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 9) Install the plate assembly to the vehicle body. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb) (1) Set the plate assembly to the vehicle. (2) Temporarily tighten the bolt (A). (3) Tighten the bolt (B). (4) Tighten the bolt (A). (5) Tighten the bolts (C) and (D).
(C) (B)
2. 6MT MODEL
1) Insert the gear shift lever from the room side. NOTE: Insert the rod and the stay, and position the lever on top of the transmission mount. 2) Mount the cushion rubber on the vehicle body. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
CS-00222
3) Move the transmission to the right side of the vehicle, and attach the joint COMPL and stay. Tightening torque: T1: 12 Nm (1.2 kgf-m, 8.9 ft-lb) T2: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
(A) CS-00314
(D)
(A)
10) Install the harness clamp to the plate. 11) Install the boot and insulator assembly, and secure with a clamp.
T1
T2
CS-00223
(A) Reverse check cable
4) Install the crossmember. <Ref. to 6MT-30, INSTALLATION, Transmission Mounting System.>

CS-00312
12) Install the front cover assembly. 13) Install the console box. <Ref. to EI-54, INSTALLATION, Console Box.> 14) Install the shift knob. 15) Check that the gear can be shifted accurately into each gear ranges.
CS-43
MT Gear Shift Lever

CONTROL SYSTEMS
5) Install the reverse check cable end, washer and snap pin to the reverse check lever. NOTE: Take care to install the snap pin in proper direction. Before installing, adjust the reverse check cable. <Ref. to CS-58, ADJUSTMENT, Reverse Check Cable.>
9) Install the plate assembly to the vehicle body. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb) (1) Set the plate assembly to the vehicle. (2) Temporarily tighten the bolt (A). (3) Tighten the bolt (B). (4) Tighten the bolt (A). (5) Tighten the bolts (C) and (D).
(C) (B)
(C) (D)
(D) (B) (A) CS-00224
(A)
CS-00582
(A) (B) (C) (D)
Reverse check cable Washer Snap pin Front side
10) Install the harness clamp to the plate assembly. 11) Install the boot and insulator assembly, and secure with a clamp.
CS-00312
AT-01331
7) Install the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 8) Install the under cover.
12) Install the front cover assembly. 13) Install the console box. <Ref. to EI-54, INSTALLATION, Console Box.> 14) Check that the gear can be shifted accurately into each gear ranges.
CS-44
MT Gear Shift Lever

CONTROL SYSTEMS
C: DISASSEMBLY
1. 5MT MODEL
1) Remove the lock wires.
5) Separate the gear shift lever and the stay.
CS-00319 (A)
6) Remove the boot, bushing and snap ring from gear shift lever.
CS-00316
(A) Lock wire

(A) (B) (A) (C)
2) Remove the rod from lever.
(B) (A) CS-00320
(C)
CS-00317
(A) O-ring (B) Bushing (C) Snap ring
(A) Rod (B) Lever (C) Stay
7) Remove the spring pin, and then remove the bushing and snap ring.
3) Separate the rod and inner boot. 4) Remove the snap ring from the stay.
(B) (A) CS-00060 (A)
(A) Spring pin (B) Bushing

CS-00318
(A) Snap ring
CS-45
MT Gear Shift Lever

CONTROL SYSTEMS
8) Remove the boss from the joint.
2. 6MT MODEL
1) Remove the spring pin from the slider.
(B)
(A) CS-00322
9) Remove the bushing and spacer from the boss.

(A) (B)
CS-00225
(A) Slider (B) Spring pin
2) Remove the slider and spring.
(A)
(A)
CS-00238
(B)
(A) Bushing (B) Spacer
10) Remove the bushing and cushion rubber from the stay.
(A) (B)
CS-00226
(A) Slider (B) Spring
(C)
3) Cut the band clip. 4) Remove the reverse check cable from the cable plate.
(B)
CS-00058
(A) Bushing B (B) Stay (C) Cushion rubber
(A) CS-00228
(A) Cable plate (B) Reverse check cable
CS-46
MT Gear Shift Lever

CONTROL SYSTEMS
5) Remove the reverse check cable from the gear shift assembly.
8) Remove the boss from the rod.

(B) (A)
CS-00232 CS-00229
6) Remove the holder and spring.
(A) Rod (B) Boss
9) Remove the rod from lever.

(A) (B) (A)
CS-00587
(A) Holder
(C)
CS-00233
7) Disassemble the lock wires. NOTE: Do not reuse the lock wire.
10) Separate the rod and inner boot. 11) Remove the snap ring from the stay.
(A) CS-00231
(A) Lock wire
(A) CS-00234
(A) Snap ring
CS-47
MT Gear Shift Lever

CONTROL SYSTEMS
12) Separate the gear shift lever and the stay.
15) Remove the bushing and spacer from the boss.

(A) (B)
CS-00235
(A)
CS-00238
13) Remove the boot and bushing from gear shift lever.
(A)
(B)
(A)
16) Remove the bushing and cushion rubber from the stay.
(C) (B)
CS-00236
(A) O-ring (B) Bushing
(A) CS-00239
14) Remove the spring pin, and then remove the bushing and snap ring.
(A) Bushing (B) Stay (C) Cushion rubber
(B)
(A) CS-00237
(A) Bushing (B) Snap ring
CS-48
MT Gear Shift Lever

CONTROL SYSTEMS
D: ASSEMBLY
1. 5MT MODEL
NOTE: Clean all the parts before assembly. Apply NIGTIGHT LYW No. 2 grease or the equivalent to each part. <Ref. to CS-5, 5MT GEAR SHIFT LEVER, COMPONENT, General Description.> 1) Mount the bushing and cushion rubber to the stay.
(A)
4) Install the snap ring to gear shift lever and install the bushing. NOTE: Apply grease to the bushing.
(B) (A) CS-00060 (B)
(A) Spring pin (B) Bushing
5) Apply grease to the bushing and O-ring, and then install to gear shift lever.
CS-00061
(A) Bushing (B) Cushion rubber
(A)
(B)
(A)
(C)
2) Install the bushing and spacer to boss.

(A) (B) CS-00320
(A) O-ring (B) Bushing (C) Snap ring

(A) CS-00238
6) Apply sufficient grease into boss, and then install the gear shift lever to the stay.
3) Using new self-locking nuts, install the boss to the joint. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
CS-00319
CS-00322
CS-49
MT Gear Shift Lever

CONTROL SYSTEMS
7) Install the washer and snap ring.
10) Install a new lock wire.
(A) (A)
CS-00318
CS-00316
(A) Snap ring
(A) Lock wire
8) Insert the gear shift lever and rod into boot hole. 9) Install the rod. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
NOTE: Install the lock wire to the stay groove. Bend the extra wire to the same direction of lock wire winding.
(A) B (A) B
(B) (A) (B) (B)
(C)
(C) CS-00317
(B)
B-B CS-00240
(A) Inner boot (B) Lock wire (C) Stay
CS-50
MT Gear Shift Lever

CONTROL SYSTEMS
2. 6MT MODEL
NOTE: Clean all the parts before assembly. Apply NIGTIGHT LYW No. 2 grease or the equivalent to each part. <Ref. to CS-6, 6MT GEAR SHIFT LEVER, COMPONENT, General Description.> 1) Mount the bushing and cushion rubber to the stay.
(C) (B)
3) Install the snap ring to gear shift lever and install the bushing. NOTE: Apply grease to the bushing.
(B)
(A) CS-00237
(A) CS-00239
(A) Bushing (B) Snap ring
4) Apply grease to the bushing and O-ring, and then install to gear shift lever.
(A) Bushing (B) Stay (C) Cushion rubber
(A)
(B)
(A)
2) Install the bushing and spacer to boss.

(A) (B) CS-00236
(A) O-ring (B) Bushing

(A) CS-00238
5) Apply sufficient grease to the boss, and then install the gear shift lever to the stay.
CS-00235
CS-51
MT Gear Shift Lever

CONTROL SYSTEMS
10) Install a new lock wire.
(A) CS-00234
(A) CS-00231
(A) Snap ring
(A) Lock wire
7) Insert the gear shift lever and rod into boot hole. 8) Install the rod. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
(B) (A)
NOTE: Install the lock wire to the stay groove. Bend the extra wire to the same direction of lock wire winding.
(A) B (A) B
(B) (B)
(C)
(C) CS-00233
9) Install the boss to the rod. Tightening torque: 12 Nm (1.2 kgf-m, 8.9 ft-lb)
B-B (B) (A) CS-00240 (B)
(A) Inner boot (B) Lock wire (C) Stay
CS-00232
(A) Rod (B) Boss
CS-52
MT Gear Shift Lever

CONTROL SYSTEMS
11) Install the holder. Tightening torque: 1.3 Nm (0.1 kgf-m, 1.0 ft-lb)
15) Use the spring pin to secure the end of the slider and the reverse check cable. NOTE: Apply grease to the moving part of slider.
(A) (B)
(A)
CS-00587 CS-00225
(A) Holder
12) Insert the reverse check cable into the boot hole. 13) Insert the reverse check cable to the gear shift assembly, and affix with a band clip. NOTE: Cut the excess band clip. Make sure that the reverse check cable is inserted into the gearshift lever with no gaps. 14) Attach the seat cushion and spring.
(A)
16) With the cable pulled (the slider is lowered), adjust the distance between the edge of cable plate and the reverse check cable to 84 mm (3.31 in), and tighten the lock nut. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
(B)
(A)
CS-00961 CS-00241
(A) 84 mm (3.31 in) (A) Spring (B) Seat cushion
17) Secure the reverse check cable to the stay clip. NOTE: Install the reverse check cable on top of the stay.
(B) (A)
CS-00243
(A) Reverse check cable (B) Clip
CS-53
MT Gear Shift Lever

CONTROL SYSTEMS
E: INSPECTION
1. 5MT MODEL
1) Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.
2) Check the swing torque of rod linked with the gear shift lever. If the torque exceeds the specifications, replace the bushing or retighten nuts. Swing torque: 3.7 N (0.38 kgf, 0.83 lbf) or less
(C) (A) (F)
(B)
(A)
(A)
(C) (A) (C) (D)
CS-00116
(A) Pivot (B) Swing torque
2. 6MT MODEL
Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.
(B)
(E)
CS-00323
(A) (B) (C) (D) (E)
Bushing Cushion rubber Spacer Boot Stay
(F) Rod
CS-00586
CS-54
Reverse Check Cable

CONTROL SYSTEMS
9. Reverse Check Cable

A: REMOVAL
1) Set the vehicle on a lift. 2) Remove the gear shift knob. 3) Remove the console box front. <Ref. to EI-54, REMOVAL, Console Box.> 4) Remove the front cover assembly. 5) Remove the spring pin from the slider.
(B)
12) Remove the snap pin and washer, and separate the reverse check cable from the reverse check lever.
(A)
(B)
(C) CS-00220
(A)
CS-00225
13) Move the transmission to the right side, and remove the stay bolts and the reverse check cable. NOTE: If the transmission is not moved aside, the stay bolts may contact the body and cause damage.
(A)
6) Remove the slider and spring.
(A) (B) (B)
CS-00245 CS-00226
(A) Slider (B) Spring
(A) Stay (B) Stay bolt
7) Cut the band clip, and separate the reverse check cable from the gear shift lever. 8) Lift up the vehicle. 9) Remove the under cover. 10) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 11) Remove the crossmember. <Ref. to 6MT-30, REMOVAL, Transmission Mounting System.>
14) Lift the stay clip, and separate the stay and the reverse check cable.
(B) (A)
CS-00243
CS-55
Reverse Check Cable

CONTROL SYSTEMS
15) Pull out the reverse check cable from underside of the vehicle to remove it. NOTE: Be careful not to damage the inner boot. 16) Loosen the lock nut, and remove the reverse check cable from the cable plate.
(B)
B: INSTALLATION
1) Insert the reverse check cable into the inner boot hole from underside of the vehicle. 2) Insert the reverse check cable into the gear shift lever assembly, and secure it with the band clip. NOTE: Cut the excess band clip. Make sure that the reverse check cable is inserted into the gearshift lever with no gaps. 3) Use the spring pin to secure the end of the slider and the reverse check cable. NOTE: Apply grease to the moving part of slider.
(A) CS-00228 (B)
(A) Cable plate (B) Reverse check cable

(A)
CS-00225
4) Lift up the vehicle. 5) With the cable pulled (the slider is lowered), adjust the distance between the edge of cable plate and the reverse check cable to 84 mm (3.31 in), and tighten the lock nut. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
(A)
CS-00961
(A) 84 mm (3.31 in)
CS-56
Reverse Check Cable

CONTROL SYSTEMS
6) Move the transmission to the right side, and install the stay. Tightening torque: T: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
(A)
9) Install the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 10) Lower the vehicle. 11) Install the front cover assembly. 12) Install the console box. <Ref. to EI-54, INSTALLATION, Console Box.> 13) Install the gear shift knob.
C: INSPECTION
1) Make sure the slider moves smoothly. If it does not move, adjust the reverse check cable, or check the slider for damage. <Ref. to CS-58, ADJUSTMENT, Reverse Check Cable.> 2) Check that the gear shifts into reverse when the slider is pulled up. If the gear is not shifted to the reverse, adjust the reverse check cable. <Ref. to CS58, ADJUSTMENT, Reverse Check Cable.> 3) Check that the gear does not shift into reverse when the slider is not pulled up. If the gear is shifted to the reverse, adjust or replace the reverse check cable. <Ref. to CS-58, ADJUSTMENT, Reverse Check Cable.>
CS-00246
(A) Stay
7) Attach the reverse check cable, washer and snap pin to the reverse check lever. NOTE: Take care to install the snap pin in proper direction.
(C) (D)
(B)
(A) CS-00224
(A) (B) (C) (D)
8) Secure the reverse check cable to the stay clip. NOTE: Install the reverse check cable on top of the stay.
(B) (A)
CS-00243
CS-57
Reverse Check Cable

CONTROL SYSTEMS
D: ADJUSTMENT
1) Set the vehicle on a lift. 2) Remove the under cover. 3) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 4) Remove the crossmember. <Ref. to 6MT-30, REMOVAL, Transmission Mounting System.> 5) Remove the snap pin and washer, and separate the reverse check cable from the reverse check lever.
7) With the cable pulled (the slider is lowered), adjust the distance between the edge of cable plate and the reverse check cable to 84 mm (3.31 in), and tighten the lock nut. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
(A)
(A) CS-00961 (B)
(A) 84 mm (3.31 in)
(C) CS-00220
8) Move the transmission to the right side, and install the stay. Tightening torque: T: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
(A)
6) Move the transmission to the right side, and remove the stay bolts and the reverse check cable. NOTE: If the transmission is not moved aside, the stay bolts may contact the body and cause damage.
(A)
CS-00246
(A) Stay
(B)
CS-00245
9) Install the crossmember. <Ref. to 6MT-30, INSTALLATION, Transmission Mounting System.> 10) Install the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.>
(A) Stay (B) Stay bolt
CS-58
Reverse Check Cable

CONTROL SYSTEMS
11) Attach the reverse check cable, washer and snap pin to the reverse check lever. NOTE: Take care to install the snap pin in proper direction.
(C) (D)
(B)
(A) CS-00224
(A) (B) (C) (D)
CS-59

CONTROL SYSTEMS

A: INSPECTION
Symptoms Select lever Possible cause Starter does not run. Back-up light does not illuminate. AT shift lock system does not operate normally. Manual mode can not be set. Up-shift is not engaged at manual mode. Down-shift is not engaged at manual mode. Corrective action Adjust the select cable and inhibitor switch, or inspect the circuit. Adjust the select cable and inhibitor switch, or inspect the circuit. Adjust the select cable and inhibitor switch, or inspect the circuit. Adjust the mode switch and select lever, or inspect the circuit. Check the shift-up switch and circuit. Check the shift-down switch and circuit.
CS-60
General Description
AUTOMATIC TRANSMISSION
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
Type Stall torque ratio Nominal mm (in) diameter Stall speed (at sea level) One-way clutch Symmetric, 3 element, single stage, 2 phase torque converter 2.05 2.35 246 (9.69) 2,200 2,700 rpm Sprag type one-way clutch
5. PLANETARY GEAR AND PLATE

Number of front sun gear teeth Number of front pinion teeth Number of front internal gear teeth Number of rear sun gear teeth Number of rear pinion teeth Number of rear internal gear teeth Number of high clutch drive plates Number of low clutch drive plates Number of reverse clutch drive plates Number of drive plates for the 2-4 brake Number of drive plates for low & reverse brake 33 21 75 42 17 75
2. OIL PUMP
Type Driving method Number of teeth Parachoid constant-displacement pump Driven by engine Inner rotor 9 Outer rotor 10
3. TRANSMISSION CONTROL ELEMENT

Type Multi-plate clutch Multi-plate brake One-way clutch (sprague type) 4-forward, 1-reverse, double-row planetary gears 3 sets 2 sets 1 set
4. TRANSMISSION GEAR RATIO

1st 2nd 3rd 4th Rev 2.785 1.545 1.000 0.694 2.272
6. SELECTOR POSITION
Transmission is in neutral, output member is fixed, engine start is possible R (Reverse) Transmission in reverse for backing up Transmission is in neutral and engine N (Neutral) start is possible 4-forward automatic gear change D (Drive) 1st m o 2nd m o 3rd m o 4th 4-forward automatic gear change SPORT mode 1st m o 2nd m o 3rd m o 4th 4-forward manual gear change Manual mode (+) (shift up) 1st o 2nd o 3rd o 4th 4-forward manual gear change Manual mode () (shift down) 1st m 2nd m 3rd m 4th Control method Wire cable type P (Park)
4AT-2
General Description
7. HYDRAULIC CONTROL AND LUBRICATION

Electronic hydraulic control [4 forward gear changes made by electronic signals of vehicle speed and accelerator (throttle) opening] Recommended materials SUBARU ATF HP IDEMITSU ATF HP CAUTION: Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble. 9.3 9.6 (9.8 10.1, 8.2 8.4) Forced feed lubrication with oil pump Automatic transmission fluid (see above)
8. COOLING AND HARNESS

Cooling system Inhibitor switch Transmission harness Liquid-cooler 12 poles 20 poles
Type
9. TRANSFER
Transfer type Number of transfer clutch drives and driven plates Control method Lubricant Reduction gear ratio Multi-plate transfer (MPT) 5 Electronic hydraulic type Same automatic transmission fluid as used in the automatic transmission 1.000 (53/53)
Fluid Alternative
Fluid capacity
2 (US qt, Imp qt)
Lubrication system Oil
10.FINAL REDUCTION GEAR

Model Front final reduction gear ratio Except for OUTBACK 4.111 (37/9) OUTBACK 4.444 (40/9)
11.RECOMMENDED GEAR OIL

(1) (2) (3) GL-5 (4) -30 -26 -15 -5 0 -22 -15 5 23 32 85W 80W 75W -90 MT-00001
( C) ( F)
15 59
25 30 77 86 90
Lubrication oil
(1) Item (2) Front differential gear oil Front differential oil capacity 2 (US qt, Imp qt)
(3) API standard (4) SAE viscosity No. and applicable temperature
1.1 1.3 (1.2 1.4, 1.0 1.1)
4AT-3
General Description
B: COMPONENT
1. TORQUE CONVERTER AND CASE
(1)
(2) (4) (3) T2
T2 (5)
(15) (6) (7) (14) (8) T1 T2
T2 (13) T3 (12) (9)
(16) (10)
(11)
AT-04882
(1) (2) (3) (4) (5) (6) (7) (8)
Pitching stopper bracket O-ring Differential oil level gauge Stay Seal pipe Oil pump shaft Clip Oil drain pipe
(9) (10) (11) (12) (13) (14) (15) (16)
Input shaft O-ring Torque converter clutch ASSY Differential gear oil drain plug Gasket Oil seal Converter case Spring pin
Tightening torque:Nm (kgf-m, ft-lb) T1: 18 (1.8, 13.3) T2: 41 (4.2, 30.2) T3: 44 (4.5, 32.5) (Aluminum gasket) 70 (7.1, 51.6) (Copper gasket)
4AT-4
General Description
2. OIL PUMP
AT-03358
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Oil pump rotor Oil pump cover Seal ring Thrust needle bearing Drive pinion shaft Roller bearing Drive pinion shim Oil pump housing Nipple Air breather hose
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Gasket O-ring Test plug Stud bolt O-ring O-ring Oil seal retainer Oil seal O-ring Drive pinion collar
(21)
Lock nut
Tightening torque:Nm (kgf-m, ft-lb) T1: 7 (0.7, 5.2) T2: 13 (1.3, 9.6) T3: 18 (1.8, 13.3) T4: 25 (2.5, 18.4) T5: 40 (4.1, 29.5) T6: 42 (4.3, 31.0) T7: 116 (11.8, 85.6)
4AT-5
General Description
3. TRANSMISSION CASE AND CONTROL DEVICE

(36)
(1)
(31) (30)
(2) (7)
(5) (6)
(37) (39) (29)
T3 T1
T6 (34)
(3)
T6
(33) (35)
(4) (32) (38)
(8)
T2
(28) T8 (27) (26) (25) (23) (22) (12) (13) (19) T5 (18) (24) T5 (16) (17) (15) (14) T1 (20) T6 (11) (10) T7 T4 (9)
T2
(21)
AT-04874
4AT-6
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) ATF level gauge Oil charge pipe O-ring Straight pin Return spring Shaft Parking pawl Parking support Gasket ATF inlet pipe Union screw O-ring Test plug Drain plug (ATF) Gasket Oil pan Magnet (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) Stud bolt (short) Stud bolt (long) Parking rod Manual plate Spring pin Detent spring Ball Spring Gasket ATF outlet pipe Union screw Oil seal Shifter arm Inhibitor switch ASSY Nipple Air breather hose (34) (35) (36) (37) (38) (39) Transmission case Plate ASSY O-ring Spring pin Transfer clutch seal Shifter arm shaft
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 6 (0.6, 4.4) T3: 12 (1.2, 8.9) T4: 13 (1.3, 9.6) T5: 18 (1.8, 13.3) T6: 25 (2.5, 18.4) T7: 40 (4.1, 29.5) T8: 45 (4.6, 33.2)
4AT-7
General Description
4. CONTROL VALVE AND HARNESS ROUTING
(2) (1) (6) (7) T1
(4) (5)
(8) (9)
(3)
T1
T1 (10)
T2 (11 )
T3
AT-04779
(1) (2) (3) (4) (5)
Stay Transmission harness O-ring O-ring Torque converter turbine speed sensor
(6) (7) (8) (9) (10) (11)
O-ring Front vehicle speed sensor O-ring Rear vehicle speed sensor Control valve body Control valve strainer
Tightening torque:Nm (kgf-m, ft-lb) T1: 7 (0.7, 5.2) T2: 8 (0.8, 5.9) T3: 10 (1.0, 7.4)
4AT-8
General Description
5. HIGH CLUTCH AND REVERSE CLUTCH
AT-00006
(1) (2) (3) (4) (5) (6) (7)
High clutch drum Lip seal D-ring Reverse clutch piston D-ring D-ring High clutch piston
(8) (9) (10) (11) (12) (13) (14)
Spring retainer Clutch cover Snap ring Driven plate (high clutch) Drive plate (high clutch) Retaining plate (high clutch) Snap ring
(15) (16) (17) (18) (19) (20) (21)
Dish plate Driven plate (reverse clutch) Drive plate (reverse clutch) Retaining plate (reverse clutch) Snap ring Thrust needle bearing High clutch hub
4AT-9
General Description
6. PLANETARY GEAR AND 2-4 BRAKE

(5) (4) (3) (2) (1) (11) (10) (9) (8) (7) (6) (19) (18) (16) (17) (16) (17) (16) (15) (14) (13) (12)
(26) (23) (22) (21) (20) (25)
(24)
AT-00007
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Thrust needle bearing Front sun gear Thrust needle bearing Snap ring Front planetary carrier Thrust needle bearing Rear sun gear Thrust needle bearing Rear planetary carrier
(10) (11) (12) (13) (14) (15) (16) (17) (18)
Washer Thrust needle bearing Rear internal gear Washer Snap ring Retaining plate Drive plate Driven plate Pressure rear plate
(19) (20) (21) (22) (23) (24) (25) (26)
Snap ring Spring retainer 2-4 brake piston D-ring D-ring 2-4 brake piston retainer 2-4 brake seal Leaf spring
4AT-10
General Description
7. LOW CLUTCH AND LOW & REVERSE BRAKE

(10) (11) (9) (8) (7) (5) (4) (3) (4) (6)
(3) (2) (1)
(16) (15) (14) (13) (12)
(21)
(23) (22)
(20) (19) (18) (17) (29) (28) (27) (30)
(28) (27) (25) (26) AT-01278
(24)
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Snap ring Retaining plate Drive plate Driven plate Dish plate Snap ring Cover Spring retainer D-ring Low clutch piston D-ring
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Low clutch drum Needle bearing Snap ring One-way clutch Snap ring Thrust needle bearing Seal ring Needle bearing One-way clutch inner race Socket bolt Spring retainer
(23) (24) (25) (26) (27) (28) (29) (30)
Return spring Snap ring Retaining plate Leaf spring Drive plate Driven plate Dish plate Low & reverse brake piston
4AT-11
General Description
8. REDUCTION GEAR
MP-T MODEL
(12)
(4) (3)
(2) (1) (10) (8) (8) (9) (8) (7) (6)
(11)
(5)
AT-04780
(1) (2) (3) (4) (5)
Seal ring Ball bearing Reduction drive gear Reduction drive shaft Drive pinion shaft
(6) (7) (8) (9) (10)
Snap ring Ball bearing Snap ring Reduction driven gear Washer
(11) (12)
Lock nut Gasket
4AT-12
General Description
9. DIFFERENTIAL GEAR
(12)
(1) (2)
(13) (11) (3) (4) (11) (13) (5) T2 (12)
(10) T1 (10) (9) (8) (7) (6) (8) (9) T1 (6) (7)
AT-00011
(1) (2) (3) (4) (5) (6)
Hypoid driven gear Pinion shaft Differential case (RH) Straight pin Differential case (LH) Taper roller bearing
(7) (8) (9) (10) (11) (12)
Oil seal O-ring Differential side retainer Lock plate Washer Differential bevel pinion
(13)
Differential bevel gear
4AT-13
General Description
10.TRANSFER AND EXTENSION CASE

MP-T MODEL
(6) (5) (7)
(6) (5) (4) (3) (14)
(1)
(2)
(13) (12)
(20) T2 (11) (10) (9) (21) (15) (22) T1 (18) (19)
(8)
T2
(17) (16) AT-01784
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Thrust needle bearing Needle bearing Snap ring Driven plate (Thick) Drive plate Driven plate (Thin) Retaining plate Snap ring Transfer clutch piston seal
(10) (11) (12) (13) (14) (15) (16) (17) (18)
Return spring Transfer clutch piston Rear drive shaft Ball bearing Seal ring Gasket Transfer clutch pipe Extension case Transmission hanger
(19) (20) (21) (22)
Oil seal Dust cover Test plug O-ring
4AT-14
General Description
11.TRANSMISSION MOUNTING
T2
(2)
T2
T4 (1) (3)
T5
T3 (4)
T1
T5 AT-03876
(1) (2)
Pitching stopper Rear cushion rubber
(3) (4)
Transmission rear crossmember Stopper
Tightening torque:Nm (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 40 (4.1, 29.5) T3: 50 (5.1, 36.9) T4: 58 (5.9, 42.8) T5: 75 (7.6, 55.3)
4AT-15
General Description
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Do not place the oil pan with its inner side facing up until it is installed, to prevent intrusion of foreign matter into the valve body. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry apart with screwdrivers or other tools. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine gear oil, SUBARU genuine ATF, and specified grease or equivalent. Do not mix gear oil, grease, etc. of different grades or manufacturers. Be sure to tighten bolts and nuts to the specified torque. Place lifts, shop jacks or rigid racks at specified locations. Apply gear oil or ATF onto sliding or revolution surfaces before installation in view of components usage. Replace deformed or damaged snap rings with new parts. Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. Avoid damaging the mating surface of the case. Before applying liquid gasket, completely remove the old liquid gasket. When disassembling the AT, be sure to use nylon gloves and paper towels. Do not use cloth gloves or waste cloth.
4AT-16
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 498575400 DESCRIPTION OIL PRESSURE GAUGE ASSY REMARKS Used for measuring oil pressure.
ST-498575400
498897200
OIL PRESSURE GAUGE ADAPTER
Used at the oil pump housing when measuring reverse clutch pressure and line pressure.
ST-498897200
498897700
OIL PRESSURE ADAPTER SET
Used for measuring transfer clutch pressure.
ST-498897700
498277200
STOPPER SET
Used for removing and installing automatic transmission assembly to engine.
ST-498277200
4AT-17
General Description
ILLUSTRATION TOOL NUMBER 398527700 DESCRIPTION PULLER ASSY REMARKS Used for removing the extension case roller bearing. Used for removing the extension oil seal. Used for removing the front differential side retainer bearing outer race. Used for removing the front differential side retainer oil seal.
ST-398527700
498057300
INSTALLER
Used for installing the extension oil seal.
ST-498057300
41099AC000
ENGINE SUPPORT ASSY
Used for supporting the engine.
ST41099AC000
498077000
REMOVER
Used for removing the differential taper roller bearing.
ST-498077000
499247400
INSTALLER
Used for installing the transfer outer snap ring. Used together with the GUIDE (499257300).
ST-499247400
4AT-18
General Description
ILLUSTRATION TOOL NUMBER 499257300 DESCRIPTION SNAP RING OUTER GUIDE REMARKS Used for installing the transfer outer snap ring. Used together with the INSTALLER (499247400).
ST-499257300
18630AA010
WRENCH COMPL RETAINER
Used for removing and installing the differential side retainer. WRENCH ASSEMBLY (499787000) can also be used.
ST18630AA010
398437700
DRIFT
Used for installing the converter case oil seal.
ST-398437700
398487700
INSTALLER
Used for installing the front differential taper roller bearing.
ST-398487700
398673600
COMPRESSOR
Used for removing and installing the clutch spring.
ST-398673600
4AT-19
General Description
ILLUSTRATION TOOL NUMBER 498255400 DESCRIPTION PLATE REMARKS Used for measuring the backlash of hypoid gear.
ST-498255400
399893600
PLIER
Used for removing and installing the clutch spring.
ST-399893600
498247001
MAGNET BASE
Used for measuring the gear backlash. Used together with DIAL GAUGE (498247100).
ST-498247001
498247100
DIAL GAUGE
Used for measuring the gear backlash. Used together with MAGNET BASE (498247001).
ST-498247100
498517000
REPLACER
Used for removing the front roller bearing.
ST-498517000
4AT-20
General Description
ILLUSTRATION TOOL NUMBER 398623600 DESCRIPTION SEAT REMARKS Used for removing the spring of the transfer clutch piston.
ST-398623600
499267300
STOPPER PIN
Used for installing the inhibitor switch.
ST-499267300
499787700
WRENCH
Used for removing and installing the drive pinion lock nut.
ST-499787700
499787500
ADAPTER
ST-499787500
398643600
GAUGE
Used for measuring total end play, extension end play and drive pinion height.
ST-398643600
4AT-21
General Description
ILLUSTRATION TOOL NUMBER 498627100 DESCRIPTION SEAT REMARKS Used for holding the low clutch piston retainer spring when installing snap ring.
ST-498627100
499577000
GAUGE
Used for measuring the mating surface of the transmission to the end face of the reduction gear. For MP-T model
ST-499577000
499737000
PULLER
Used for removing the reduction driven gear assembly.
ST-499737000
499737100
PULLER SET
Used for removing the reduction drive gear assembly.
ST-499737100
498077600
REMOVER
Used for removing the ball bearing.
ST-498077600
4AT-22
General Description
ILLUSTRATION TOOL NUMBER 498937110 DESCRIPTION HOLDER REMARKS Used for removing and installing the drive pinion lock nut.
ST-498937110
498677100
COMPRESSOR
Used for installing the 2-4 brake snap ring.
ST-498677100
498437000
HIGH CLUTCH PISTON GUIDE
Used for installing the high clutch piston.
ST-498437000
498437100
LOW CLUTCH PISTON GUIDE
Used for installing the low clutch piston.
ST-498437100
899580100
INSTALLER
Used for press-fitting the ball bearing of the transfer clutch.
ST-899580100
4AT-23
General Description
ILLUSTRATION TOOL NUMBER 28399SA010 DESCRIPTION OIL SEAL PROTECTOR REMARKS Used for installing the axle shaft.
ST28399SA010
18675AA000
DIFFERENTIAL SIDE OIL SEAL INSTALLER
Used for installing the differential side retainer oil seal.
ST18675AA000
398497701
SEAT
Used for installing the needle bearing.
ST-398497701
899524100
(1)
PULLER SET
Use only the bolt. Used together with PULLER SET (499737100). Used together with PULLER (499737000). 1. Puller 2. Cap
(2)
ST-899524100
499247300
INSTALLER
Used for installing the oil pump housing retainer oil seal.
ST-499247300
4AT-24
General Description
ILLUSTRATION TOOL NUMBER 398791600 DESCRIPTION REMOVER REMARKS Used for removing the shifter arm spring pin.
ST-398791600
1B022XU0
ST1B022XU0
2. GENERAL TOOL
TOOL NAME Depth gauge Thickness gauge Micrometer Spring scale Circuit tester TORX T70 Push/pull gauge REMARKS Used for measuring the transmission end play. Used for measuring clearance of the clutch, brake and oil pump. Used for measuring thickness of the drive pinion. Used for measuring the starting torque of the drive pinion. Used for measuring resistance and voltage. Used for removing and installing differential gear oil drain plug. Used for measuring the piston stroke of each clutch.
4AT-25

2. Automatic Transmission Fluid

A: INSPECTION
NOTE: The level of ATF varies with fluid temperature. Pay attention to the ATF temperature when checking ATF level. 1) Raise the ATF temperature by driving a distance of 5 10 km (3 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 80C (158 176F) on Subaru Select Monitor. <Ref. to 4AT(diag)-17, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> 2) Park the vehicle on a level surface. 3) After selecting all positions (P, R, N, D), set the select lever in P range. Idle the engine for 1 or 2 minutes, and measure the ATF level.
(A) (B) (C)
L F HOT
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the drain plug (ATF) and completely drain the ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 3) Check the ATF condition. <Ref. to 4AT-27, CONDITION CHECK, Automatic Transmission Fluid.> 4) Perform replacement with a new gasket, and tighten the drain plug (ATF). Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
(B)
F COLD L
(B) (C) AT-01323 AT-04829
(A) Oil pan (B) Drain plug (ATF)
5) Lower the vehicle. 6) Pour ATF from the oil charge pipe. Recommended fluid: <Ref. to 4AT-3, HYDRAULIC CONTROL AND LUBRICATION, SPECIFICATION, General Description.> CAUTION: Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble. Capacity: Fill with the same amount of ATF that was drained from drain plug hole. Capacity when transmission is overhauled: 9.3 9.6 2 (9.8 10.1 US qt, 8.2 8.4 Imp qt) 7) Bleed the air of control valve. <Ref. to 4AT-59, Air Bleeding of Control Valve.> 8) Check the level and leaks of ATF. <Ref. to 4AT26, INSPECTION, Automatic Transmission Fluid.>
4) Make sure that the ATF level is higher than mid level between the upper and lower marks of the HOT side. If the fluid level is below the lower mark, check the transmission for leaks. If there are leaks, it is necessary to repair or replace gaskets, oil seals, plugs or other parts. 5) If the ATF level is below the center point between upper and lower level marks, add the recommended ATF until the fluid level is above the center point between the upper and lower level marks. CAUTION: Be careful not to exceed the upper level. Be wary of the ATF level when filling. If the ATF is filled to the upper level while the transmission is cold, it is in an overfilled condition and the oil will over flow. 6) Check ATF level after raising ATF temperature to 70 80C (158 176F) by running the vehicle again or by idling the engine.
4AT-26

C: CONDITION CHECK
NOTE: When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF.
Fluid condition Large amount of metallic pieces are found. Thick and varnish-form fluid. Clouded fluid or bubbles are found in fluid. Trouble and possible cause Excessive wear of the internal of the transmission body. Burned clutch, etc. Water mixed in fluid. Corrective action Replace ATF and check if AT operates correctly. Replace ATF and check the AT body or vehicle for faulty. Replace ATF and check the water entering point.
4AT-27
Differential Gear Oil

3. Differential Gear Oil

A: INSPECTION
1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Make sure the level gauge is inserted correctly and in the proper orientation. 4) Remove the oil level gauge again, and check the level of differential gear oil. If the differential gear oil level is below L line, add oil to bring the level up to F line. NOTE: To prevent overfilling the differential gear oil, do not fill oil to the F line or more.
(A) (A)
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the differential gear oil drain plug using TORX bit T70, and drain the differential gear oil completely. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or causing fires. If differential gear oil is spilled on the exhaust pipe, wipe it off completely. 3) Replace the gasket with a new part and tighten the differential gear oil drain plug using the TORX bit T70. Tightening torque: Aluminum gasket 44 Nm (4.5 kgf-m, 32.5 ft-lb) Copper gasket 70 Nm (7.1 kgf-m, 51.6 ft-lb)
AT-04863 (A)
(B) (C)
(B) AT-04830
(A) Oil pan (B) Differential gear oil drain plug
4) Lower the vehicle. 5) Fill the differential with differential gear oil from the level gauge hole. Recommended gear oil: <Ref. to 4AT-3, RECOMMENDED GEAR OIL, SPECIFICATION, General Description.> Gear oil capacity: 1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp qt) 6) Check the level of differential gear oil. <Ref. to 4AT-28, INSPECTION, Differential Gear Oil.>
4AT-28
Road Test
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diagnose the condition of automatic transmission. NOTE: When performing the test, do not exceed posted speed limit.
3) Check the ATF temperature using the Subaru Select Monitor. NOTE: Make sure that the ATF temperature is between 50 100C (122 212F). If the temperature is low, warm up the ATF by running the vehicle. 4) Start the engine, so that the lock-up duty can be read on the data display of the Subaru Select Monitor. 5) Drive the vehicle at a constant speed of 35 40 km/h (22 25 MPH). 6) Read the lock-up duty while vehicle is running. Standard 25 45% NOTE: The reading may be slightly lower on a free roller. Slip lock-up control is not operating if the lock-up duty is 5% or less, or when the lock-up duty goes down immediately after starting to rise. In these cases, improper ATF or deterioration of the ATF may be the cause. Check the amount of ATF or replace the fluid, then recheck.
2. D RANGE SHIFT FUNCTION

Check shifting between 1st mo 2nd mo 3rd mo 4th while driving on normal city streets.
3. D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Check the shock level during kick-down at the same time.
5. ENGINE BRAKE OPERATION

Check the 3rd gear engine brake when shifting down from 4th to 3rd range while driving in 4th gear of manual mode [50 60 km/h (31 37 MPH)]. Check the 2nd gear engine brake when shifting down from 3rd to 2nd range while driving in 3rd gear of manual mode [40 50 km/h (25 31 MPH)]. Check the 1st gear engine brake when shifting down from 2nd to 1st range while driving in 2nd gear of manual mode [20 30 km/h (12 19 MPH)].
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more and shift to the P range. Check that the vehicle does not move when the parking brake is released.
8. NOISE AND VIBRATION

Check for noise and vibration while driving and during shifting.
6. LOCK-UP FUNCTION
When the accelerator is lightly depressed while driving on a flat road in D range, check that rpm does not change abruptly. Check slip lock-up with following procedure. Subaru Select Monitor is required for judgement. Before starting the check, make sure that no DTC is displayed using the Subaru Select Monitor. If there is a DTC, perform the corrective action according to the DTC. Recheck to see that the DTC has been cleared, then start the slip lock-up check. 1) The check is to be performed on a flat and straight road or on a free roller. NOTE: Slip lock-up will not operate when the vehicle is lifted up off of its wheels, since there is no surface resistance. When checking on the free roller, the driving resistance will be slightly inadequate. It will be easier to judge if the foot brake is lightly applied while performing the check. 2) Connect the Subaru Select Monitor.
9. TRANSFER CLUTCH
Check for tight corner braking phenomenon when the vehicle is moved forward with the steering fully turned.
10.OIL LEAKAGE
After the driving test, inspect for oil leaks.
4AT-29
Stall Test
5. Stall Test
A: INSPECTION
NOTE: The stall test is extremely important in diagnosing the condition of an automatic transmission and engine. The test is necessary to measure the engine stall speeds in R and 2nd of manual mode. Purposes of the stall test: Operational check of the automatic transmission clutch Operational check of the torque converter clutch Engine performance check 1) Check that the throttle valve fully opens. 2) Check that the engine oil level is correct. 3) Check that the coolant level is correct. 4) Check that the ATF level is correct. 5) Check that the differential gear oil level is correct. 6) Increase the ATF temperature to 70 to 80C (158 to 176F) by idling the engine for approximately 30 minutes (with select lever set to N or P). 7) Place the wheel chocks at the front and rear of all wheels and apply the parking brake. 8) Move the manual linkage to ensure it operates properly, and then set to the 2nd gear of manual mode.
AT-02205
9) While pressing hard on the foot brake pedal, slowly depress the accelerator pedal to full throttle. 10) When the engine speed stabilizes, quickly record the engine speed and release accelerator pedal. 11) Shift the select lever to N range, and cool down the engine by idling it for one minute or more. 12) If the stall speed in 2nd gear of manual mode is higher than specifications, low clutch slipping and 2-4 brake slipping may occur. To identify this, conduct the same test as above in R range.
4AT-30
Stall Test
13) Perform the stall tests with the select lever in D range. NOTE: Do not continue the stall test for 5 seconds or more at a time (from closed throttle, fully open throttle to stall speed reading). Failure to follow this instruction will cause the engine oil and ATF to deteriorate and the clutch and brake to be adversely affected. Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the P or N range and with the idle speed of 1,200 rpm or less. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. Stall speed (at sea level): 2,200 2,700 rpm
Stall speed (at sea level) Below specified value Range 2nd gear on manual mode, R Cause Throttle valve is not fully open Engine malfunction One-way clutch of the torque converter is slipping Line pressure too low Low clutch slipping One-way clutch malfunctioning Line pressure too low Reverse clutch slipping Low & reverse brake slipping Line pressure too low Low clutch slipping 2-4 brake slipping
Over specified value
2nd gear of manual mode
4AT-31
Time Lag Test

6. Time Lag Test

A: INSPECTION
NOTE: When the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before shock is felt. This is used for checking the condition of the low clutch, reverse clutch, low & reverse brake and one-way clutch. Perform the test at normal operation fluid temperature of 70 80C (158 176F). Be sure to allow a one minute or more interval between tests. Make three measurements and take the average value. 1) Fully apply the parking brake. 2) Start the engine. Check the idle speed (A/C OFF). 3) Shift the select lever from N to D range. Using a stop watch, measure the time which takes from shifting the lever until the shock is felt. Time-lag Standard: 1.2 seconds or less If N o D time lag is longer than specified: Line pressure too low Low clutch worn One-way clutch not operating properly D-ring worn 4) In the same manner, measure the time lag of N o R. Time-lag Standard: 1.5 seconds or less If N o R time lag is longer than specified: Line pressure too low Reverse clutch worn Low & reverse brake worn D-ring worn
4AT-32
Line Pressure Test

7. Line Pressure Test

A: MEASUREMENT
NOTE: If the clutch or brake shows a signs of slipping or shift feel is not correct, check the line pressure. Excessive shock during up-shift or if shifting takes place at a higher point than for normal conditions, this may be due to the line pressure being too high. Slippage or inability to operate the vehicle may, in most cases, be due to insufficient oil pressure for the operation of clutch, brake or control valve. 1) Line pressure measurement (under no load): (1) Before measuring line pressure, lift up the vehicle. (2) Maintain the ATF temperature at approx. 70 80C (158 176F) during measurement. (ATF will reach the temperature above after idling the engine for approx. 30 minutes with the select lever in N or P.) 2) Line pressure measurement (under heavy load) (1) Before measuring line pressure, apply both the foot and parking brakes with all wheels chocked on both front and rear of all wheels. (Same conditions as for a stall test) (2) Measure the line pressure when the select lever is in R or 2nd of manual mode with engine under stall conditions. (3) Measure the line pressure within 5 seconds after shifting the select lever to each position. (If the line pressure needs to be measured again, allow the engine to idle and cool it down for more than 1 minute.) (4) Maintain the ATF temperature at approx. 70 80C (158 176F) during measurement. (ATF will reach the temperature above after idling the engine for approx. 30 minutes with the select lever in N or P.) 3) Remove the test plug and attach the ST instead. ST 498897200 OIL PRESSURE GAUGE ADAPTER
4) Connect the ST1 with ST2. ST1 498897200 OIL PRESSURE GAUGE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY 5) Check for duty ratio changes by adjusting the acceleration pedal position using the Subaru Select Monitor.
Standard line pressure Line pressure Throttle Line pressure duty ratio valve angle kPa (kg/cm2, psi) (%) 1,000 1,300 25 35 Full open (10.2 13.3, 145 188) 1,500 1,850 15 25 Full open (15.3 18.9, 217 268) 500 800 35 43 Full closed (5.1 8.2, 72 116)
Range position Manual mode (2nd) R
6) Remove the ST and install the test plug. Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
(A)
AT-04673
(A) Test plug
4AT-33
Transfer Clutch Pressure Test

8. Transfer Clutch Pressure Test

A: INSPECTION
Check the transfer clutch pressure in accordance with the following chart in the same manner as line pressure. <Ref. to 4AT-33, Line Pressure Test.> ST 498897700 OIL PRESSURE ADAPTER SET ST 498575400 OIL PRESSURE GAUGE ASSY NOTE: Before setting to FWD mode, install the spare fuse on the FWD mode switch.
(A)
AT-00021
(A) Test plug
If no oil pressure is produced or if it does not change in AWD mode, there may be a problem in the transfer duty solenoid or control valve body. If oil pressure is produced in FWD mode, there is the same problem as the AWD mode.
Range position ON duty ratio (%) Acceleration opening angle (%) Standard transfer clutch pressure kPa (kg/cm2, psi) FWD AWD mode mode 1,000 1,200 (10.2 12.2, 145 174) 500 700 (5.1 7.1, 72 101) 0 0 (0, 0)
95 Manual mode (2nd)
Fully opened (100) Adjust ON Duty ratio to 60%. Fully closed (0) Fully closed (0)
60
N or P
4AT-34
Automatic Transmission Assembly

9. Automatic Transmission Assembly

A: REMOVAL
1) Set the vehicle on a lift. 2) Open the front hood and support with the hood stay. 3) Disconnect the ground cable from battery. 4) Remove the air intake chamber and intake boot. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 5) Remove the air intake chamber stay.
9) Separate the torque converter clutch assembly from drive plate. CAUTION: Be careful not to damage the mounting bolts. Be careful not to drop bolts into the converter case. (1) Remove the V-belt covers. (2) Remove the service hole plug. (3) Remove the bolts which hold the torque converter clutch assembly to the drive plate. (4) Place the wrench on the crank pulley bolt, and remove all the bolts while rotating the crank pulley a little bit at a time.
AT-01327
6) Disconnect the following connectors and terminals.
AT-00102
(B)
(A) AT-04902
ST AT-00804
(A) Transmission harness connectors (B) Transmission ground terminal
11) Remove the ATF level gauge. NOTE: Plug the opening to prevent entry of foreign particles into the transmission fluid.
7) Remove the starter. <Ref. to SC(H4SO)-6, REMOVAL, Starter.> 8) Remove the pitching stopper.
AT-01330 AT-03877
12) Remove the throttle body. <Ref. to FU(H4SO)12, REMOVAL, Throttle Body.>
4AT-35

13) Disconnect the engine harness, then remove the harness connector from the engine harness bracket. 14) Remove the engine harness bracket.
21) Remove the heat shield cover.
AT-01331
22) Remove the drain plug (ATF) to drain the ATF.

AT-04581 (A)
15) Remove the pitching stopper bracket. 16) Set the ST. ST 41099AC000 ENGINE SUPPORT ASSY
(B)
AT-04829 ST

AT-02167
17) Remove the bolts which hold upper side of transmission to engine.
23) Disconnect the ATF cooler hoses from the pipes of the transmission side, and remove the oil charge pipe.
AT-04831 AT-00106
18) Lift up the vehicle. 19) Remove the under cover. 20) Remove the front, center and rear exhaust pipes and the muffler. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.>
24) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 25) Remove the shift select cable. <Ref. to CS-28, REMOVAL, Select Cable.> 26) Remove the brackets (two) which hold front stabilizer.
4AT-36

27) Remove the bolt securing the ball joint of the front arm to housing.
32) Remove the transmission rear crossmember from the vehicle.
AT-00809
AT-03697
28) Pull out the front drive shaft from the transmission. (1) Using a tire lever or a crow bar, etc., pull out until the front drive shaft transmission side joint slides move smoothly. NOTE: Place cloth between the tire lever or bar and the transmission in order to avoid damaging the transmission side retainer. (2) Hold the transmission side joint of the front drive shaft by hand and extract the housing from the transmission while pressing the housing outward, so as not to stretch the boot. 29) Remove the bolts which hold the clutch housing cover. 30) Remove the bolts and nuts which hold lower side of transmission to engine.
33) While lowering the transmission jack gradually, fully retract the engine support, and then tilt the engine rearward. NOTE: Retract the support until the clearance between front crossmember and converter case becomes approx. 10 mm (0.39 in). 34) Remove the transmission. NOTE: Remove the transmission and torque converter as a single unit from engine.
AT-04857
35) Remove the rear cushion rubber from the transmission assembly.
AT-00108
31) Place the transmission jack under the transmission. NOTE: Make sure that the support plates of transmission jack do not touch the oil pan.
4AT-37

B: INSTALLATION
1) Replace the differential side oil seal with a new part. <Ref. to 4AT-45, REPLACEMENT, Differential Side Retainer Oil Seal.> NOTE: When a new oil seal has been installed, replacement is not required. 2) Install the rear cushion rubber to the transmission assembly. Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb) 3) Attach the ST to the converter case. ST 498277200 STOPPER SET
5) Install the transmission rear crossmember. Tightening torque: T1: 35 Nm (3.6 kgf-m, 25.8 ft-lb) T2: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
T1 T2 T2
AT-03698
6) Remove the transmission jack. 7) Tighten the bolts and nuts which hold the lower side of transmission to the engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
ST AT-00103
4) Install the transmission onto the engine. (1) Lift up the transmission gradually using transmission jack.
AT-00108
8) Install the clutch housing cover bolts. 9) Lower the vehicle. 10) Connect the engine and transmission. (1) Remove the ST from converter case. NOTE: When removing the ST, be careful not to drop it into converter case. (2) Install the starter. <Ref. to SC(H4SO)-6, INSTALLATION, Starter.> (3) Tighten the bolts which hold the upper side of the transmission to the engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT-04857
(2) Insert the engine side stud bolt into the transmission bolt hole. (3) While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward and connect.
AT-00106
4AT-38

11) Install the torque converter clutch assembly to the drive plate. CAUTION: Be careful not to damage the mounting bolts. Be careful not to drop bolts into the converter case. (1) Tighten the bolts which hold the torque converter clutch assembly to the drive plate. (2) Place the wrench on the crank pulley bolt, and remove all the bolts while rotating the crank pulley a little bit at a time. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
15) Install the pitching stopper bracket. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
(A)
AT-04642
(A) Pitching stopper bracket
16) Install the throttle body. <Ref. to FU(H4SO)-12, INSTALLATION, Throttle Body.> 17) Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
AT-00102
(3) Fit the plug to service hole. (4) Install the V-belt cover. 12) Remove the ST.
T2
T1
AT-03878 ST
AT-02167
13) Install the engine harness bracket. Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
18) Lift up the vehicle. 19) Replace the circlip of the front drive shaft with a new part. 20) Apply grease to the oil seal lip. 21) Attach the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
ST AT-00110 AT-04581
14) Install the harness connector to engine harness bracket, then connect the harness.
22) Align and insert the spline of the front drive shaft to the splines of the differential bevel gear, and remove the ST.
4AT-39

23) Insert the front drive shaft into the transmission securely by pressing the front housing from the outside.
27) Always tighten the rubber bushing locations with wheels in full contact with the ground and the vehicle at curb weight. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 28) Install the shift select cable onto select lever. <Ref. to CS-30, INSTALLATION, Select Cable.> 29) Install the oil charge pipe, and connect the ATF cooler hoses to the pipe.
AT-00111
24) Install the ball joint into the housing. 25) Tighten the attachment bolts. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT-04831
30) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 31) Install the heat shield cover.
AT-00809
26) Install the stabilizer to the front crossmember. NOTE: Install the bushing (on front crossmember side) while aligning it with the paint mark on the stabilizer. Make sure the bushing and stabilizer are marked with the same identification colors (paint mark) when installing.
AT-01331
32) Install the rear exhaust pipe and muffler. <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> 33) Install the front and center exhaust pipe. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> 34) Install the under cover. 35) Lower the vehicle. 36) Install the ATF level gauge.
FS-00050
(1) Identification mark on stabilizer (2) Bushing identification color
AT-01330
4AT-40

37) Connect the following connectors and terminals.
(B)
(A) AT-04902
(A) Transmission harness connectors (B) Transmission ground terminal
38) Install the air intake chamber stay. Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb) 39) Install the air intake chamber and intake boot. <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 40) Connect the ground cable to battery. 41) Pour in the ATF using the oil charge pipe. <Ref. to 4AT-26, Automatic Transmission Fluid.> 42) Check the differential gear oil level. <Ref. to 4AT-28, Differential Gear Oil.> 43) Check the select lever operation. <Ref. to 4AT46, INSPECTION, Inhibitor Switch.> 44) Bleed the air of control valve. <Ref. to 4AT-59, Air Bleeding of Control Valve.> 45) Check the ATF level. <Ref. to 4AT-26, INSPECTION, Automatic Transmission Fluid.> 46) Execute the learning control promotion. <Ref. to 4AT(diag)-18, FACILITATION OF LEARNING CONTROL, OPERATION, Subaru Select Monitor.> 47) Perform the road test. <Ref. to 4AT-29, Road Test.>
4AT-41
Transmission Mounting System

10.Transmission Mounting System

A: REMOVAL
1. PITCHING STOPPER
1) Remove the air intake chamber and intake boot. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Remove the pitching stopper.
6) Remove the transmission rear crossmember.
AT-03697
7) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
AT-03877
2. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER

1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the front, center and rear exhaust pipes and the muffler. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> 4) Remove the heat shield cover.
T1
T2
AT-03878
2) Install the air intake chamber and intake boot. <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.>
AT-01331
5) Set the transmission jack under transmission. NOTE: Make sure that the support plate of transmission jack does not touch the oil pan.
4AT-42


1) Install the rear cushion rubber. Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb) 2) Install the transmission rear crossmember. Tightening torque: T1: 35 Nm (3.6 kgf-m, 25.8 ft-lb) T2: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
T1 T2 T2
C: INSPECTION
If problems are found in the following inspection, repair or replace the part.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or damaged. Check that there are no cracks, hardening or damage on rubber parts.

Make sure that the crossmember is not bent or damaged. Check that there are no cracks, hardening, or damage on cushion rubbers.
AT-03698
3) Remove the transmission jack. 4) Install the heat shield cover.
AT-01331
5) Install the front, center and rear exhaust pipes, and the muffler. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> 6) Lower the vehicle. 7) Connect the ground cable to battery.
4AT-43
Extension Case Oil Seal

11.Extension Case Oil Seal

A: INSPECTION
Confirm that there is no ATF leakage from the joint of the transmission and propeller shaft. If a leak is found, replace the oil seal and inspect the propeller shaft. <Ref. to 4AT-44, REPLACEMENT, Extension Case Oil Seal.>
8) Using the ST, remove the oil seal. ST 398527700 PULLER ASSY 9) Using the ST, install the oil seal. ST 498057300 INSTALLER 10) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 11) Install the heat shield cover.
B: REPLACEMENT
1) Lift up the vehicle. 2) Clean the transmission exterior. 3) Remove the drain plug (ATF) and completely drain the ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 4) Perform replacement with a new gasket, and tighten the drain plug (ATF). Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-01331
12) Install the rear exhaust pipe and muffler. <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> 13) Fill with ATF. <Ref. to 4AT-26, Automatic Transmission Fluid.> 14) Bleed the air of control valve. <Ref. to 4AT-59, Air Bleeding of Control Valve.> 15) Check the level and leaks of the ATF. <Ref. to 4AT-26, INSPECTION, Automatic Transmission Fluid.>
(B)
AT-04829
5) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> 6) Remove the heat shield cover.
AT-01331
7) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.>
4AT-44
Differential Side Retainer Oil Seal

12.Differential Side Retainer Oil Seal

A: INSPECTION
Check for leakage of gear oil from differential side retainer oil seal part. If there is an oil leak, replace the oil seal and inspect the drive shaft.
7) Using the ST, install the differential side retainer oil seal by lightly tapping with a hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
ST
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the front exhaust pipe and center exhaust pipe. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.> 3) Remove the differential gear oil drain plug using TORX bit T70, and then drain differential gear oil. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or causing fires. If differential gear oil is spilled on the exhaust pipe, wipe it off completely.
(A)
AT-00029
8) Apply gear oil to the oil seal lips. 9) Using the ST, install the front drive shaft. <Ref. to DS-22, INSTALLATION, Front Drive Shaft.> ST 28399SA010 OIL SEAL PROTECTOR 10) Install the front exhaust pipe and the center exhaust pipe. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> 11) Lower the vehicle. 12) Fill with differential gear oil through the oil level gauge hole. <Ref. to 4AT-28, Differential Gear Oil.> 13) Check the level of differential gear oil. <Ref. to 4AT-28, INSPECTION, Differential Gear Oil.>
(B) AT-04830
4) Perform replacement with a new gasket, and tighten the differential gear oil drain plug. Tightening torque: Aluminum gasket 44 Nm (4.5 kgf-m, 32.5 ft-lb) Copper gasket 70 Nm (7.1 kgf-m, 51.6 ft-lb) 5) Separate the front drive shaft from the transmission. <Ref. to DS-22, REMOVAL, Front Drive Shaft.> 6) Remove the differential side retainer oil seal using driver wrapped with vinyl tape etc.
4AT-45
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
When the driving condition or starter motor operation is improper, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: Also check that there is no continuity in the ignition circuit when the select lever is in the R and D ranges. If the inhibitor switch does not operate, check for poor contact of the connector on transmission side.
Range Signal sent to TCM P R N D P/N R Pin No. 43 42 41 48 12 11 10 9
3) Check that there is continuity at equal points when the select lever is turned 1.5 in both directions from the N range. If there is continuity in only one direction or in other points, adjust the inhibitor switch. <Ref. to 4AT-46, ADJUSTMENT, Inhibitor Switch.>
(C) (A) (B) (A)
AT-02206
(A) Continuity does not exist. (B) Continuity exists. (C) 1.5
Ignition circuit Back-up light circuit
4) Repeat the above inspection in other gear ranges. If there are faults, adjust the select cable. <Ref. to CS-32, ADJUSTMENT, Select Cable.>
B: ADJUSTMENT
(A)
( 4 ) (3 ) (2 ) (1 ) ( 8 ) (7 ) (6 ) (5 ) (12) (11) (10) (9 )
1) Set the select lever to N range. 2) Loosen the two bolts holding the inhibitor switch. 3) Insert the ST as vertical as possible into the holes of the shifter arm and switch body. ST 499267300 STOPPER PIN
AT-00030
(A) Inhibitor switch connector
ST AT-04866
4) Tighten the two bolts holding the inhibitor switch. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 5) Repeat the inspection of the inhibitor switch. If the inhibitor switch is determined to be faulty, replace it.
4AT-46
Inhibitor Switch
C: REMOVAL
1) Set the vehicle on a lift. 2) Set the select lever to N range. 3) Lift up the vehicle. 4) Remove the front and center exhaust pipes. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> 5) Remove the snap pin and washer from the shifter arm.
7) Remove the spring pin and remove the shifter arm. ST 398791600 REMOVER
(B) (A)
(D) (B)
AT-04868
(A) Spring pin (B) Shifter arm
(C)
8) Remove the two inhibitor switch securing bolts.

(A) AT-04867
(A) (B) (C) (D)
Shifter arm Snap pin Select cable Washer
(A)
6) Remove the plate assembly from the transmission case.

AT-04785
(A) Inhibitor switch
9) Remove the inhibitor switch from the transmission.
(B)
(A) CS-00955 (A)
AT-04786
10) Disconnect the inhibitor switch harness connector from the inhibitor switch.
4AT-47
Inhibitor Switch
D: INSTALLATION
1) Connect the inhibitor switch harness connector to the inhibitor switch. 2) Install the inhibitor switch to the transmission case.
7) Install the plate assembly to the transmission. Tightening torque: T: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T
(A)
(A) (B) CS-00956 AT-04786
3) Install the shifter arm and affix with a new spring pin.
8) Attach the washer and snap pin to the shifter arm.
(D) (B) (B) (A) (C) AT-04868 (A) AT-04867
(A) Spring pin (B) Shifter arm
4) Move the shifter arm to the neutral position. 5) Using the ST, tighten the two bolts holding the inhibitor switch. ST 499267300 STOPPER PIN Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
(A) (B) (C) (D)
Shifter arm Snap pin Select cable Washer
9) Install the front and center exhaust pipe. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> 10) Lower the vehicle. 11) Inspect the inhibitor switch. <Ref. to 4AT-46, INSPECTION, Inhibitor Switch.>
(B) (A)
ST
AT-04869
(A) Inhibitor switch (B) Shifter arm
6) Install the select cable to the shifter arm.
4AT-48
Front Vehicle Speed Sensor

14.Front Vehicle Speed Sensor

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 4) Disconnect the transmission harness connector.
11) Remove the front, center and rear exhaust pipes and the muffler. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> 12) Remove the heat shield cover.
(A)
AT-01331 AT-04655
(A) Transmission harness connectors
5) Remove the pitching stopper. <Ref. to 4AT-42, REMOVAL, Transmission Mounting System.> 6) Remove the transmission harness connector from stay. 7) Lift up the vehicle. 8) Clean the transmission exterior. 9) Remove the drain plug (ATF) to drain the ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 10) Perform replacement with a new gasket, and tighten the drain plug (ATF). Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
13) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 14) Place the transmission jack under the transmission. NOTE: Make sure that the support plate of transmission jack does not touch the cross. 15) Remove the transmission rear crossmember bolt.
AT-00043
16) Lower the transmission jack. NOTE: Do not separate the transmission jack and transmission. 17) Remove the ATF inlet and outlet pipes.
(B)
AT-04829
CAUTION: When removing the outlet pipe, be careful not to lose the ball and spring used together with the retaining screw.
4AT-49

18) Remove the front vehicle speed sensor and torque converter turbine speed sensor.
(A) (B)
B: INSTALLATION
1) Pass the transmission harness assembly through the hole of the transmission case.
AT-00044
(A) Front vehicle speed sensor (B) Torque converter turbine speed sensor
AT-00048
2) Connect the control valve connector and transmission ground. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
(A)
19) Disconnect the connector from the rear vehicle speed sensor.
(A)
(B)
AT-02207 AT-04832
(A) Rear vehicle speed sensor
20) Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan. 21) Disconnect the control valve connector and transmission ground terminal.
(A)
(A) Transmission ground terminal (B) Control valve connector
3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
(B)
AT-04832 AT-02742
(A) Transmission ground terminal (B) Control valve connector
22) Remove the transmission harness assembly.
4AT-50

4) Fill the 3 locations of the transmission case excluding the bolt holes with liquid gasket. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
AT-01331
AT-04837
5) Install the oil pan by equally tightening the bolts. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 6) Install the front vehicle speed sensor and torque converter turbine speed sensor. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb) 7) Connect the connector to the rear vehicle speed sensor. 8) Install the ATF inlet and outlet pipes. NOTE: Use a new copper washer. Tightening torque: T1: 25 Nm (2.5 kgf-m, 18.4 ft-lb) T2: 40 Nm (4.1 kgf-m, 29.5 ft-lb) T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
12) Install the front, center and rear exhaust pipes, and the muffler. <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> 13) Lower the vehicle. 14) Install the transmission harness connector to the stay. 15) Install the pitching stopper. <Ref. to 4AT-42, INSTALLATION, Transmission Mounting System.> 16) Install the air intake chamber. <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 17) Fill with the same amount of ATF as drained. <Ref. to 4AT-26, Automatic Transmission Fluid.> 18) Bleed the air of control valve. <Ref. to 4AT-59, Air Bleeding of Control Valve.> 19) Inspect the level of ATF. <Ref. to 4AT-26, INSPECTION, Automatic Transmission Fluid.> 20) Execute the learning control promotion. <Ref. to 4AT(diag)-18, FACILITATION OF LEARNING CONTROL, OPERATION, Subaru Select Monitor.>
T2
T3 T1 AT-04676
9) Install the transmission rear crossmember bolt. Tightening torque: 75 Nm (7.6 kgf-m, 55.3 ft-lb) 10) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.>
4AT-51
Rear Vehicle Speed Sensor

15.Rear Vehicle Speed Sensor

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Disconnect the connector from the rear vehicle speed sensor.
(A)
AT-02207
5) Remove the rear vehicle speed sensor.
AT-01341
B: INSTALLATION
Install in the reverse order of removal. NOTE: Replace the O-ring with a new part. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb)
4AT-52
Torque Converter Turbine Speed Sensor

16.Torque Converter Turbine Speed Sensor

A: REMOVAL
For removal procedure of the torque converter turbine speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to 4AT-49, REMOVAL, Front Vehicle Speed Sensor.>
B: INSTALLATION
For installation procedure of the torque converter turbine speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to 4AT-50, INSTALLATION, Front Vehicle Speed Sensor.>
4AT-53
Control Valve Strainer

17.Control Valve Strainer

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Clean the transmission exterior. 5) Remove the drain plug (ATF) to drain the ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself.
11) Remove the control valve strainer tightening bolt, and remove control valve strainer from the control valve body.
AT-04834
B: INSTALLATION
1) Check the control valve body for dust and other foreign matter. 2) Attach a new control valve strainer to the control valve body. (1) Apply ATF to the entire perimeter of the Oring on the control valve strainer.
AT-03117
6) Perform replacement with a new gasket, and tighten the drain plug (ATF). Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 7) Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan.
CAUTION: When applying ATF, avoid adhesion of dust and foreign matter on the O-ring. (2) Install the control valve strainer to the control valve body from the O-ring side. CAUTION: If the control valve strainer is pushed in at an angle, the O-ring may be damaged. Be sure to push in the control valve strainer straight to install. (3) Tighten the three bolts. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb)
AT-03118
8) Remove the magnet. 9) Clean the magnet. 10) Completely remove the remaining liquid gasket on the transmission case and oil pan.
AT-04834
4AT-54
Control Valve Strainer

3) Attach the magnet at the specified position of the oil pan.
C: INSPECTION
Check the control valve strainer for holes, damages or adhesion of dust and other foreign particles.
AT-02743
AT-02742
5) Fill the 3 holes aside from the bolt holes in the transmission case, with liquid gasket. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
AT-04837
6) Install the oil pan by equally tightening the bolts. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 7) Fill ATF from the oil charge pipe. <Ref. to 4AT26, Automatic Transmission Fluid.> 8) Bleed the air of control valve. <Ref. to 4AT-59, Air Bleeding of Control Valve.> 9) Check the ATF level. <Ref. to 4AT-26, INSPECTION, Automatic Transmission Fluid.>
4AT-55
Control Valve Body

18.Control Valve Body

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Clean the transmission exterior. 5) Remove the drain plug (ATF) to drain the ATF. CAUTION: After running the engine or after idling for a long time, the ATF is hot. Be careful not to burn yourself.
10) Completely remove the remaining liquid gasket on the transmission case and oil pan. 11) Disconnect the control valve connector.
AT-04838
12) Remove the oil cooler pipe.
AT-02928
6) Perform replacement with a new gasket, and tighten the drain plug (ATF). Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 7) Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan. 13) Remove the control valve body.
AT-00059
NOTE: The control valve body is replaced as an assembly only, because it is a non-disassembly part.
AT-04833
AT-02929
8) Remove the magnet.
AT-02743
9) Clean the magnet.
4AT-56
Control Valve Body

B: INSTALLATION
1) Check the control valve body for dust and other foreign matter. 2) Temporarily attach the control valve body to the transmission. 3) Install the oil cooler pipe. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
AT-02743
AT-00059
4) Tighten the bolts equally. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
(A) (2)
(2)
(2) (2) (2) (2) (2) (2) AT-04839 AT-02742
(2) (2) (2) (1) (1)
8) Fill the 3 holes aside from the bolt holes in the transmission case, with liquid gasket. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
(A) Transmission ground Bolt length mm (in) (1) 35 (1.38) (2) 30 (1.18)
5) Connect the control valve connector.
AT-04837
9) Install the oil pan by equally tightening the bolts. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 10) Fill ATF from the oil charge pipe. <Ref. to 4AT26, Automatic Transmission Fluid.> 11) Bleed the air of control valve body. <Ref. to 4AT-59, Air Bleeding of Control Valve.> 12) Check the ATF level. <Ref. to 4AT-26, INSPECTION, Automatic Transmission Fluid.>
AT-04838
4AT-57
Control Valve Body

13) Execute the learning control promotion. <Ref. to 4AT(diag)-18, FACILITATION OF LEARNING CONTROL, OPERATION, Subaru Select Monitor.>
C: INSPECTION
Check parts for holes, damages or adhesion of dust and other foreign particles.
4AT-58
Air Bleeding of Control Valve

19.Air Bleeding of Control Valve

When ATF is drained from the automatic transmission, make sure to bleed air from the control valve after filling with the specified amount of ATF. Perform the procedures according to the message displayed on the Subaru Select Monitor.
B: PROCEDURE
1. PREPARATION FOR AIR BLEEDING
1) Cool down until the ATF temperature displayed on the Subaru Select Monitor is 60C (140F) or less. 2) Move the select lever to P range. 3) Fully apply the parking brake. 4) Lift up the vehicle. CAUTION: While working, be sure to keep the lower edge of the tires 30 cm or more above the ground as vehicle will vibrate. 5) Connect the Subaru Select Monitor to data link connector. 6) Turn the ignition switch to ON. 7) Turn off all switches causing an electrical load, such as headlights, A/C, seat heater and rear defogger.
4AT-59
Air Bleeding of Control Valve

2. AIR BLEEDING
CAUTION: Do not turn the power of the Subaru Select Monitor OFF during work, and do not disconnect the data link connector. 1) Select {Learning and inspection mode related to AT} in the Transmission Diagnosis screen of the Subaru Select Monitor. 2) Select {AT air bleeding mode} in the Learning and inspection mode related to AT screen of the Subaru Select Monitor. 3) Follow the messages displayed on the Subaru Select Monitor screen when working. NOTE: When AT air bleeding in progress, the SPORT light in the combination meter will flash at 2 Hz, and air bleed will start. When the indicator light flashing at 2 Hz turns off, the following message will appear on the screen. 4) Air bleed is complete when a message AT air bleeding normally ended. is displayed. NOTE: If a communication error occurs during air bleed, start the AT air bleeding over from the beginning. If the message Execute AT learning again after fixing troubles of the vehicle appears during air bleed, select [OK] and display the DTC list. After repairing the locations indicated by the DTC, start the AT air bleeding over from the beginning. If the message AT air bleeding ended abnormally is displayed, start the AT air bleeding over from the beginning. When communication error occurs during air bleeding, select lever does not shift occasionally. If select lever does not shift, turn the ignition switch to OFF before operating the lever.
Message AT air bleeding ended abnormally. Main reasons for abnormal termination A failure was detected during AT air bleed The accelerator was stepped on during AT air bleed. An unspecified operation was performed during AT air bleed Brake pedal not stepped on firmly enough. Parking brake not applied strongly enough. Abnormal idle speed increase, etc.
4AT-60
Transmission Control Module (TCM)

20.Transmission Control Module (TCM)

A: REMOVAL
1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover and disconnect the connector. 3) Disconnect the connector from TCM.
(A) (B)
AT-04950
(A) Transmission control module (TCM) (B) Brake pedal
4) Remove the TCM.
B: INSTALLATION
1) Install the TCM. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
(A) (B)
AT-04950
(A) Transmission control module (TCM) (B) Brake pedal
2) Connect the connector to the TCM. 3) Install in the reverse order of removal. 4) Execute the learning control promotion. <Ref. to 4AT(diag)-18, FACILITATION OF LEARNING CONTROL, OPERATION, Subaru Select Monitor.>
4AT-61
ATF Cooler Pipe and Hose

21.ATF Cooler Pipe and Hose

A: REMOVAL
1) Set the vehicle on a lift. 2) Remove the battery. 3) Lift up the vehicle. 4) Remove the under cover. 5) Remove the heat shield cover.
8) Disconnect the ATF cooler pipe from frame.
CO-02355
6) Disconnect the ATF cooler hose from the radiator. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
AT-01347
9) Remove the ATF inlet pipe and outlet pipe. CAUTION: When disconnecting the outlet pipe, be careful not to lose the ball and spring used together with the retaining screw.
(A)
AT-01345
7) Disconnect the ATF cooler hoses from the pipes. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
(B) AT-04675
(A) ATF inlet pipe (B) ATF outlet pipe
AT-04831
4AT-62

B: INSTALLATION
1) Install the ATF inlet pipe and outlet pipe along with new washers. Tightening torque: T1: 25 Nm (2.5 kgf-m, 18.4 ft-lb) T2: 40 Nm (4.1 kgf-m, 29.5 ft-lb) T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
3) Connect the ATF cooler hose to the pipe on the transmission side. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
T2
T3 T1 AT-04676
AT-04831
2) Install the ATF cooler pipe to frame.
4) Connect the ATF cooler hose to the pipe on the radiator side. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
AT-01345
5) Install the heat shield cover. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb)
AT-01347
CO-02355
6) Install the under cover. 7) Install the battery. 8) Fill the ATF. <Ref. to 4AT-26, Automatic Transmission Fluid.> NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.
4AT-63

C: INSPECTION
Repair or replace any faulty hoses, pipes, clamps, and washers found in the inspection below. 1) Check for ATF leaks in joints between the transmission, radiator, pipes, and hoses. 2) Check the clamp for deformation. 3) Lightly bend the hose and check for cracks in the surface or other damages. 4) Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was installed by pressing with your fingernail. 5) Check for peeling, cracks, and deformation at the tip of the hose.
4AT-64
Air Breather Hose

22.Air Breather Hose

A: REMOVAL
1) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Disconnect the air breather hose.
AT-00099
(A) Air breather hose (Transmission case) (B) Air breather hose (Oil pump housing)
B: INSTALLATION
1) Install the air breather hose.
AT-00099
(A) Air breather hose (Transmission case) (B) Air breather hose (Oil pump housing)
C: INSPECTION
Make sure the hose is not cracked or clogged.
4AT-65
Oil Charge Pipe

23.Oil Charge Pipe

A: REMOVAL
1) Remove the air intake chamber. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Remove the oil charge pipe, and then remove the O-ring from the flange side.
(A)
(B) AT-04677
(A) ATF level gauge (B) Oil charge pipe
B: INSTALLATION
1) Apply ATF on a new O-ring and install together with the oil charge pipe. NOTE: Use new bolts. Tightening torque: 38 Nm (3.9 kgf-m, 28.0 ft-lb)
(A)
(B) AT-04677
C: INSPECTION
Make sure the oil charge pipe is not deformed or damaged.
4AT-66
Torque Converter Clutch Assembly

24.Torque Converter Clutch Assembly

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter clutch assembly and oil pump shaft horizontally. NOTE: Be sure not to scratch the inside of bushing in oil pump shaft.
B: INSTALLATION
1) When the oil pump shaft is removed, install the shaft to converter case. 2) Install the oil pump shaft to the torque converter clutch assembly, and make sure the clip is secured on the groove. 3) Apply ATF to the O-ring and insert on the input shaft while rotating the shaft slowly by hand. Normal protrusion A: 50 55 mm (1.97 2.17 in)
AT-02384 AT-00113
A Measured value
3) Remove the input shaft. NOTE: When the torque converter clutch assembly is removed, the input shaft will also come off.
4) While holding the torque converter clutch assembly by hand, carefully install it to the converter case. Take care not to damage the bushing. Do not allow the oil pump shaft bushing to touch the stator shaft section of the oil pump cover inappropriately. 5) Slowly rotate the shaft by hand to engage the splines securely, then check that dimension A is within the specified range. Dimension A: 2.7 2.9 mm (0.106 0.114 in)
A
AT-00114
4) Remove the oil pump shaft from torque converter clutch assembly as necessary.
AT-04448
A Measured value
6) Install the transmission assembly to the vehicle. <Ref. to 4AT-38, INSTALLATION, Automatic Transmission Assembly.>
C: INSPECTION
Make sure the ring gear and protrusion of the torque converter clutch assembly end are not deformed or damaged.
4AT-67
Extension Case
25.Extension Case
A: REMOVAL
1) Remove the transmission assembly. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor.
(A)
B: INSTALLATION
1) Apply vaseline to the contact surface, and attach the selected thrust needle bearing to the end surface of the reduction drive gear. NOTE: Install the thrust needle bearing in the correct direction. 2) Install a new gasket. 3) Install the extension case to transmission case. 4) Tighten bolts to secure the extension case. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-02207
3) Separate the transmission case and extension case section.

AT-04584
5) Install the rear vehicle speed sensor. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb)
(A)
AT-04584
AT-02207
6) Install the transmission assembly. <Ref. to 4AT38, INSTALLATION, Automatic Transmission Assembly.>
4AT-68
Extension Case
C: DISASSEMBLY
1) Hit the extension case lightly with a plastic hammer, and take out the transfer clutch. NOTE: Be careful not to damage the oil seal of the extension case.
D: ASSEMBLY
1) Press-fit the new oil seal using ST and the press. ST 498057300 INSTALLER 2) Press-fit the dust cover. 3) Install the transfer clutch pipe to the extension case while being careful not to deform the pipe.
(A)
(B) (B)
(A) AT-04656 AT-00120
(A) Extension case (B) Transfer clutch
(A) Extension case (B) Transfer pipe
2) Remove the transfer clutch pipe while being careful not to deform the pipe.
(A)
4) Install the transfer clutch assembly to the case. NOTE: Be careful not to damage the seal ring. Insert the transfer clutch assembly all the way to the bottom of the bearing shoulder.
(A)
(B)
AT-00120
(A) Extension case (B) Transfer clutch pipe
(B) AT-00125
3) Remove the dust cover from extension case. 4) Remove the oil seal from the extension case.
(A) Transfer clutch ASSY (B) Extension case
E: INSPECTION
Blow with compressed air to make sure the transfer pipe and extension case routes are not clogged or leaking. Inspect the extension end play, and adjust it to within the standard value. <Ref. to 4AT-74, ADJUSTMENT, Transfer Clutch.>
4AT-69
Transfer Clutch
26.Transfer Clutch
A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Remove the extension case, and then remove the transfer clutch. <Ref. to 4AT-68, REMOVAL, Extension Case.> <Ref. to 4AT-69, DISASSEMBLY, Extension Case.>
C: DISASSEMBLY
1) Remove the seal ring.
B: INSTALLATION
1) Select the thrust needle bearing. <Ref. to 4AT74, ADJUSTMENT, Transfer Clutch.> 2) Install the transfer clutch assembly to the case.
(A) AT-00127
(A) Seal ring (B) Rear drive shaft
2) Remove the ball bearing using the ST and the press. ST 498077600 REMOVER
(B) AT-00125
3) Tighten the bolts to secure the case. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-00128
3) Using a flat tip screwdriver, etc. remove the snap ring, and take out the retaining plate, drive plate and driven plate.
AT-04584
AT-00129
(A) Snap ring (B) Rear drive shaft
4AT-70
Transfer Clutch
4) Using the ST1, ST2 and ST3, remove the snap ring, then take out the return spring and transfer clutch piston seal. ST1 399893600 PLIER ST2 398673600 COMPRESSOR ST3 398623600 SEAT
ST1 ST2
D: ASSEMBLY
1) Install the transfer clutch piston.
(A)
ST3 (A) (B) AT-00132
(B)
(A) Transfer clutch piston (B) Rear drive shaft

AT-00130
(A) Snap ring (B) Transfer clutch piston seal
2) Install the return spring to transfer clutch piston.
5) Apply compressed air to the rear drive shaft, to remove the transfer clutch piston.
(A)
(B)
AT-00133
(A) Return spring (B) Rear drive shaft

AT-00131
3) Apply ATF to the lip of transfer clutch piston seal, then install.
(B)
(A)
AT-00134
(A) Transfer clutch piston seal (B) Rear drive shaft
4AT-71
Transfer Clutch
4) Attach the ST to the rear drive shaft. ST 499257300 SNAP RING OUTER GUIDE
ST
7) Install the driven plate, drive plate, retaining plate and snap ring.
(A)
(A) AT-00135 AT-00138
(A) Rear drive shaft
(A) Snap ring
5) Install the snap ring to the ST. ST 499257300 SNAP RING OUTER GUIDE
(A) (B) ST
8) Apply compressed air to see if the assembled parts move smoothly.
AT-00136
AT-00139
6) Install the snap ring to the rear drive shaft using ST1 and ST2. ST1 499257300 SNAP RING OUTER GUIDE ST2 499247400 INSTALLER
9) Check clearance between the snap ring and pressure plate. <Ref. to 4AT-73, INSPECTION, Transfer Clutch.> 10) Press-fit new ball bearing using ST. ST 899580100 INSTALLER
ST
ST2 (A) ST1
(A)
AT-00140 (B) AT-00137
(A) Ball bearing
4AT-72
Transfer Clutch
11) Apply vaseline to a new seal ring and attach to the seal ring groove of the rear drive shaft. NOTE: While installing the seal ring, not to stretch the seal ring excessively.
(B)
E: INSPECTION
Inspect the drive plate facing for wear and damage. Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation. Inspect the D-ring for damage. Inspect the extension end play, and adjust it to within the standard value. <Ref. to 4AT-74, ADJUSTMENT, Transfer Clutch.> 1) Check the clearance between the snap ring and retaining plate. 2) Before measuring clearance, place same thickness shims on both sides to prevent the retaining plate from tilting. 3) If the clearance exceeds the service limits, replace the plate set (drive plate and driven plate), and select and adjust a retaining plate to be within the initial standard value. Initial standard: 0.7 1.1 mm (0.028 0.043 in) Limit thickness: 1.6 mm (0.063 in)
(A)
AT-00141
(A) Seal ring (B) Rear drive shaft
12) Install the transfer clutch assembly while taking care not to damage the seal ring.
(A)
(B) AT-00125
AT-00142
Part No. 31593AA151 31593AA161 31593AA171 31593AA181
Retaining plate Thickness mm (in) 3.3 (0.130) 3.7 (0.146) 4.1 (0.161) 4.5 (0.177)
4) Check for tight corner braking phenomenon when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures. (1) With the steering wheel held at fully turned position, drive the vehicle in D range and with vehicle speed at approx. 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approx. ten times each, while repeating acceleration and braking intermittently. (2) If the tight corner braking phenomenon still persists, drive the vehicle again in a circle for several laps.
4AT-73
Transfer Clutch
F: ADJUSTMENT
1) Measure the distance A from the end of ST to the rear drive shaft using the ST. ST 398643600 GAUGE
ST
A AT-01029
A Measured value
2) Measure distance B from the transmission case mating surface to the end of ST using ST1 and ST2. ST1 398643600 GAUGE ST2 499577000 GAUGE
ST2 ST1
AT-02210
B Measured value
3) Calculation formula: T = A B + 35.4 mm [T = A B + 1.3937 in] T: Thrust needle bearing thickness A: Distance from the end of the ST to end of rear drive shaft B: Distance from the mating surface of the transmission case to the end of the ST
Thrust needle bearing Part No. Thickness mm (in) 806536020 3.8 (0.150) 806535030 4.0 (0.157) 806535040 4.2 (0.165) 806535050 4.4 (0.173) 806535060 4.6 (0.181) 806535070 4.8 (0.189) 806535090 5.0 (0.197)
4AT-74
Reduction Driven Gear

27.Reduction Driven Gear

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor, and separate the extension case from transmission case. <Ref. to 4AT-68, REMOVAL, Extension Case.> 3) Set the range select lever to the P range. 4) Lift the crimped section, and then remove the lock nut.
(B)
B: INSTALLATION
1) Set the range select lever to the P range. 2) Using a plastic hammer, install the reduction driven gear assembly and the new washer, and tighten the new drive pinion lock nut. Tightening torque: 100 Nm (10.2 kgf-m, 73.8 ft-lb)
(B)
(A)
(A) AT-02212
(A) Reduction driven gear (B) Reduction drive gear

AT-02212
5) Using the ST1 and ST2, extract the reduction driven gear. ST1 499737000 PULLER ST2 899524100 PULLER SET
(B)
3) After tightening, stake the lock nut securely. 4) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. <Ref. to 4AT-68, INSTALLATION, Extension Case.> 5) Install the transmission assembly to the vehicle. <Ref. to 4AT-38, INSTALLATION, Automatic Transmission Assembly.>
ST2 ST1
(A) AT-04870
4AT-75

C: DISASSEMBLY
1) Remove the snap ring from reduction driven gear.
D: ASSEMBLY
1) Install the snap ring to reduction driven gear. 2) Install the new ball bearing to reduction driven gear using press.
(A) (A)
AT-00156 AT-00158
(A) Snap ring (A) Ball bearing
2) Remove the ball bearing from reduction driven gear using ST. ST 498077600 REMOVER
(A) ST
3) Install the snap ring to reduction driven gear.
(A)
AT-00156 AT-00157
(A) Snap ring (A) Ball bearing
3) Remove the snap ring from reduction driven gear.
E: INSPECTION
Make sure the ball bearing and gear is not deformed or damaged.
4AT-76
Reduction Drive Gear

28.Reduction Drive Gear

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor, and separate the extension case from transmission case. <Ref. to 4AT-68, REMOVAL, Extension Case.> 3) Remove the reduction driven gear. <Ref. to 4AT75, REMOVAL, Reduction Driven Gear.> 4) Using the ST, extract the reduction drive gear assembly. ST1 499737100 PULLER SET ST2 899524100 PULLER SET
(A)
C: DISASSEMBLY
1) Take out the seal ring.
(A)
(B)
AT-00161
(A) Seal ring (B) Reduction drive shaft
ST1
2) Remove the ball bearing using ST. ST 498077600 REMOVER
(A) ST2 AT-00159
ST
(A) Reduction drive gear ASSY
(B)
B: INSTALLATION
1) Install the reduction drive gear assembly. NOTE: Press-fit it to the bottom of bearing shoulder completely.
(A) Ball bearing (B) Reduction drive gear
AT-00162
3) Apply vaseline to the outer surface of seal ring and shaft groove.
(A)
(A)
AT-02213 AT-00163
(A) Reduction drive gear ASSY
(A) Reduction drive gear
2) Install the reduction driven gear. <Ref. to 4AT75, INSTALLATION, Reduction Driven Gear.> 3) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. <Ref. to 4AT-68, INSTALLATION, Extension Case.> 4) Install the transmission assembly to the vehicle. <Ref. to 4AT-38, INSTALLATION, Automatic Transmission Assembly.>
4AT-77

D: ASSEMBLY
1) Press-fit the reduction drive gear to shaft. 2) Press-fit the new ball bearing into reduction drive gear. 3) Apply vaseline onto the seal ring outer surface and shaft grooves. 4) Apply ATF to new seal rings and install them.
(A)
(B)
AT-00161
(A) Seal ring (B) Reduction drive shaft
E: INSPECTION
Rotate the bearing by hand, and check that it rotates smoothly. Check parts for holes, damage or adhesion of dust and other foreign particles. Inspect the extension end play, and adjust it to the standard value. <Ref. to 4AT-74, ADJUSTMENT, Transfer Clutch.>
4AT-78
Parking Pawl
29.Parking Pawl
A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor, and separate the extension case from transmission case. <Ref. to 4AT-68, REMOVAL, Extension Case.> 3) Remove the reduction drive gear. <Ref. to 4AT77, REMOVAL, Reduction Drive Gear.> 4) Remove the parking pawl, return spring and shaft.
(A) (B)
AT-02214
(A) Return spring (B) Parking pawl
B: INSTALLATION
1) Install the parking pawl, return spring and shaft.
(A) (B)
AT-02214
(A) Return spring (B) Parking pawl
2) Install the reduction drive gear. <Ref. to 4AT-77, INSTALLATION, Reduction Drive Gear.> 3) Install the rear vehicle speed sensor and extension case. <Ref. to 4AT-68, INSTALLATION, Extension Case.> 4) Install the transmission assembly to the vehicle. <Ref. to 4AT-38, INSTALLATION, Automatic Transmission Assembly.>
C: INSPECTION
Check the tab of the parking pole on the reduction gear for wear or other damage.
4AT-79
Converter Case
30.Converter Case
A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter clutch assembly. <Ref. to 4AT-67, REMOVAL, Torque Converter Clutch Assembly.> 3) Remove the input shaft.
9) Remove the converter case alignment bolt, and then separate the transmission case and converter case by lightly tapping with a plastic hammer. NOTE: Be careful not to damage the oil seal and bushing in the converter case with the oil pump cover. Do not loosen the rubber seal.
AT-04678
10) Remove the seal pipe.

AT-00114
4) Lift up the lever on the rear side of transmission harness connector, and then disconnect it from the stay. 5) Disconnect the inhibitor switch connector from the stay.
(B) (A) AT-00176
(A) Seal pipe
AT-01351
11) Remove the front differential assembly. <Ref. to 4AT-95, REMOVAL, Front Differential Assembly.> 12) Remove the oil seal from converter case.
(A) Transmission harness connectors (B) Inhibitor switch connector
6) Remove the air breather hose. <Ref. to 4AT-65, REMOVAL, Air Breather Hose.> 7) Remove the oil charge pipe. <Ref. to 4AT-66, REMOVAL, Oil Charge Pipe.> 8) Remove the ATF inlet and outlet pipes. <Ref. to 4AT-62, REMOVAL, ATF Cooler Pipe and Hose.>
4AT-80
Converter Case
B: INSTALLATION
1) Check the appearance of each component and clean them. 2) Press-fit the new oil seal to the converter case using the ST. ST 398437700 DRIFT
7) Apply proper amount of liquid gasket to the entire matching surface of converter case. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
(B)
(A) AT-00179 AT-00177
3) Install the front differential assembly to the case. <Ref. to 4AT-95, INSTALLATION, Front Differential Assembly.> 4) Install the right and left side retainers. <Ref. to 4AT-99, ADJUSTMENT, Front Differential Assembly.> 5) Install new seal pipe to converter case.
(A) THREE BOND 1215 (B) Rubber seal
8) Install the converter case without damaging bushing and oil seal. NOTE: Use new bolts for the oil charge pipe. Tightening torque: Oil charge pipe section 38 Nm (3.9 kgf-m, 28.0 ft-lb) Excluding the oil charge pipe section 41 Nm (4.2 kgf-m, 30.2 ft-lb)
AT-00176
(A) Seal pipe
6) Install new rubber seal to the converter case.

(A) AT-04678
AT-00178
9) Insert the inhibitor switch connector and transmission harness connector onto the stay. 10) Install the air breather hose. <Ref. to 4AT-65, INSTALLATION, Air Breather Hose.> 11) Install the ATF cooler pipe. <Ref. to 4AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 12) Install the oil charge pipe with O-ring. <Ref. to 4AT-66, INSTALLATION, Oil Charge Pipe.>
(A) Rubber seal
4AT-81
Converter Case
13) Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion. Normal protrusion A: 50 55 mm (1.97 2.17 in)
AT-03204
A Measured value
14) Install the torque converter clutch assembly. <Ref. to 4AT-67, INSTALLATION, Torque Converter Clutch Assembly.> 15) Install the transmission assembly to the vehicle. <Ref. to 4AT-38, INSTALLATION, Automatic Transmission Assembly.>
C: INSPECTION
Measure the backlash, and then adjust it to be within standard values. <Ref. to 4AT-92, ADJUSTMENT, Drive Pinion Shaft Assembly.>
4AT-82
Oil Pump Housing

31.Oil Pump Housing

A: REMOVAL
13) Place two wooden blocks on the workbench, and stand the transmission case with the rear end facing down. NOTE: Be careful not to scratch the rear mating surface of the transmission case. Check the height of the wooden blocks to avoid damaging the parking rod protruding from the mating surface, and the drive pinion.
55mm (2.17in) AT-04862 AT-00114
4) Lift up the lever on the rear side of transmission harness connector, and then remove it from the stay. 5) Remove the inhibitor switch connector from the stay. 6) Remove the oil charge pipe. <Ref. to 4AT-66, REMOVAL, Oil Charge Pipe.> 7) Remove the ATF inlet and outlet pipes. <Ref. to 4AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 8) Separate the converter case and transmission case. <Ref. to 4AT-80, REMOVAL, Converter Case.> 9) Separate the transmission case and extension case section. <Ref. to 4AT-68, REMOVAL, Extension Case.> 10) Remove the reduction drive gear. <Ref. to 4AT77, REMOVAL, Reduction Drive Gear.> 11) Remove the reduction driven gear. <Ref. to 4AT-75, REMOVAL, Reduction Driven Gear.> 12) Loosen the oil pump housing mounting bolts.
14) Remove the oil pump housing and adjusting thrust washer.
(A)
AT-00182
(A) Oil pump housing
AT-01034
4AT-83
Oil Pump Housing

B: INSTALLATION
1) Secure the oil pump housing with two nuts and a bolt. Tightening torque: 42 Nm (4.3 kgf-m, 31.0 ft-lb)
(A)
AT-03204 AT-01035
A Measured value
(A) Oil pump housing
2) Install the converter case to the transmission case assembly. <Ref. to 4AT-81, INSTALLATION, Converter Case.> 3) Install the reduction driven gear. <Ref. to 4AT75, INSTALLATION, Reduction Driven Gear.> 4) Install the reduction drive gear. <Ref. to 4AT-77, INSTALLATION, Reduction Drive Gear.> 5) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. <Ref. to 4AT-68, INSTALLATION, Extension Case.> 6) Insert the inhibitor switch connector and transmission harness connector onto the stay.
(B) (A)
AT-01351
7) Install the ATF cooler pipe. <Ref. to 4AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 8) Install the oil charge pipe together with an Oring. <Ref. to 4AT-66, INSTALLATION, Oil Charge Pipe.>
4AT-84
Oil Pump Housing

C: DISASSEMBLY
1. OIL PUMP COVER
1) Remove the four seal rings.
2. OIL SEAL RETAINER

1) Remove the oil seal retainer.
(A) (B)
(A) AT-00183 AT-00189
(A) Seal ring
(A) Oil seal retainer (B) Drive pinion shaft
2) Remove attachment bolts, then remove the cover by lightly tapping the end of the stator shaft.
(B) (A)
2) Remove the O-ring.
(A)
AT-03361 AT-00190
(A) O-ring
(A) Oil pump cover (B) Oil pump housing
3) Remove the oil seal from the oil seal retainer.

(A)
3) Remove the oil pump inner and outer rotors.

(B) (A)
(B)
AT-03360
AT-01036
(A) Oil seal (B) Oil seal retainer
(A) Inner rotor (B) Outer rotor
4AT-85
Oil Pump Housing

D: ASSEMBLY
1. OIL PUMP COVER
1) Install the oil pump rotor assembly to oil pump housing.
(B) (A)
4) Apply vaseline to the oil seal retainer and new seal rings, and install them. After installing, adjust the tooth contact with the drive pinion backlash. <Ref. to 4AT-88, ADJUSTMENT, Oil Pump Housing.> NOTE: There are two types of seals. They are identified by color. Install at the proper positions by referring to the figure.
(A) (B) AT-01036
(A) Inner rotor (B) Outer rotor
2) Align both pivots with the pivot holes of the cover, and then install the oil pump cover while being careful not to apply excessive force to the pivots. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(B) (A)
AT-01307
(A) Seal ring (Black) (B) Seal ring (Brown)
2. OIL SEAL RETAINER

1) Apply ATF to two new oil seals and install them to the oil seal retainer in the proper direction using the ST. ST 499247300 INSTALLER
(A)
AT-00190
(A) Oil pump cover (B) Oil pump housing

(B)
3) After assembling, turn the oil pump shaft to check for smooth rotation of rotor.
AT-03360
(A) Oil seal (B) Oil seal retainer
4AT-86
Oil Pump Housing

2) Apply ATF to a new O-ring and attach to the oil seal retainer. Install the seal to the oil pump housing bore.
E: INSPECTION
1) Check the seal ring and oil seal for breaks and damage. 2) Check other parts for dents or faults. 3) Oil pump rotor assembly selection (1) Tip clearance Install the inner rotor and outer rotor to the oil pump. With rotor gears facing each other, measure the crest-to-crest clearance. Tip clearance: 0.02 0.15 mm (0.0008 0.0059 in)
(A)
AT-03361
(A) (C)
(A) O-ring
3) Install the oil seal being careful not to damage oil seal lip, and secure it using three bolts. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb)
(B)
AT-01038
(B)
(A) Thickness gauge (B) Inner rotor (C) Outer rotor
(A) AT-00183
(2) Side clearance Set a depth gauge to oil pump housing, then measure the oil pump housing-to-rotor clearance. Side clearance: 0.02 0.04 mm (0.0008 0.0016 in)
(A)
(A) Oil seal retainer (B) Drive pinion shaft
(C) (B)
AT-01039
(A) Depth gauge (B) Inner rotor (C) Outer rotor
4AT-87
Oil Pump Housing

(3) If the depth and/or side clearance are not within the specification, replace the oil pump rotor assembly.
Part No. 15008AA060 15008AA070 15008AA080 Oil pump rotor assembly Thickness mm (in) 11.37 11.38 (0.4476 0.4480) 11.38 11.39 (0.4480 0.4484) 11.39 11.40 (0.4484 0.4488)
3) Calculation of total end play Select a suitable bearing race from the table below so that clearance C will be within 0.25 to 0.55 mm (0.0098 to 0.0217 in). C = (L + G) 2
C L G 2 Clearance between concave section of high clutch and end of clutch drum support Length from case mating surface to the concave portion of the high clutch Gasket thickness [0.28 mm (0.0110 in)] Height from the oil pump housing mating surface to the upper surface of the oil pump cover with the thrust needle bearing.
G
Measure the total end play and adjust it to be within specifications. <Ref. to 4AT-88, ADJUSTMENT, Oil Pump Housing.>
F: ADJUSTMENT
1) Using the ST, measure the length L, from the mating surface of the transmission to the recessed portion of the high clutch drum. ST 398643600 GAUGE
L ST
AT-00196
L AT-00194
L Measured value
2) Using the ST, measure the length L from the oil pump housing mating surface to the top surface of the oil pump cover with the thrust needle bearing. ST 398643600 GAUGE
ST
Thrust needle bearing Part No. Thickness mm (in) 806528050 4.1 (0.161) 806528060 4.3 (0.169) 806528070 4.5 (0.177) 806528080 4.7 (0.185) 806528090 4.9 (0.193) 806528100 5.1 (0.201)
4) After completing the total end play adjustment, insert the bearing race into the high clutch race. Apply vaseline, and install the thrust needle bearing to the oil pump cover. 5) After correctly installing the new gasket to the case mating surface, carefully install the oil pump housing assembly. Be careful to avoid hitting the drive pinion against the inside of case. 6) Install both parts with dowel pins aligned. Make sure there is no clearance at the mating surface.
AT-00195
2 Measured value
4AT-88
Drive Pinion Shaft Assembly

32.Drive Pinion Shaft Assembly

A: REMOVAL
B: INSTALLATION
1) Assemble the drive pinion shaft assembly to the oil pump housing. NOTE: Be careful not to bend the shim. Be careful not to press-fit the pinion into housing bore. Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
AT-00114
AT-01252
4) Lift up the lever on the rear side of transmission harness connector, and then disconnect it from the stay. 5) Disconnect the inhibitor switch connector from the stay. 6) Disconnect the air breather hose. <Ref. to 4AT65, REMOVAL, Air Breather Hose.> 7) Remove the oil charge pipe. <Ref. to 4AT-66, REMOVAL, Oil Charge Pipe.> 8) Remove the ATF inlet and outlet pipes. <Ref. to 4AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 9) Separate the converter case and transmission case. <Ref. to 4AT-80, REMOVAL, Converter Case.> 10) Separate the transmission case and extension case section. <Ref. to 4AT-68, REMOVAL, Extension Case.> 11) Remove the reduction drive gear. <Ref. to 4AT77, REMOVAL, Reduction Drive Gear.> 12) Remove the reduction driven gear. <Ref. to 4AT-75, REMOVAL, Reduction Driven Gear.> 13) Remove the drive pinion shaft mounting bolt and remove the drive shaft assembly from oil pump housing.
2) Join the torque converter case with the transmission case. <Ref. to 4AT-81, INSTALLATION, Converter Case.> 3) Install the reduction driven gear. <Ref. to 4AT75, INSTALLATION, Reduction Driven Gear.> 4) Install the reduction drive gear. <Ref. to 4AT-77, INSTALLATION, Reduction Drive Gear.> 5) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. <Ref. to 4AT-68, INSTALLATION, Extension Case.> 6) Insert the inhibitor switch connector and transmission harness connector onto the stay. 7) Install the air breather hose. <Ref. to 4AT-65, INSTALLATION, Air Breather Hose.> 8) Install the ATF inlet and outlet pipes. <Ref. to 4AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 9) Install the oil charge pipe with O-ring.
AT-01252
4AT-89

3) Separate the rear roller bearing and outer race from the drive pinion shaft using a press.
(A)
AT-00198
(A) Outer race

AT-03204
A Measured value
4) Separate the front roller bearing from the drive pinion shaft using a press and the ST. ST 498517000 REPLACER
(A) ST
C: DISASSEMBLY
1) Flatten the lock nut tab, and then remove the lock nut while holding the rear spline part of the drive pinion shaft using ST1 and ST2. Pull out the drive pinion collar. ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER
AT-00199
(A) Front roller bearing
ST3
ST2 ST1
AT-00197
4AT-90

D: ASSEMBLY
1) Using the ST, measure drive pinion shaft measurement A. ST 398643600 GAUGE
5) Tighten a new lock nut using the ST. Calculate the lock washer and lock nut specifications using following formula. T2 = L2/(L1 + L2) T1 T1: 116 Nm (11.8 kgf-m, 85.6 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example:
Torque wrench length m (in) 0.4 (15.75) 0.45 (17.72) 0.5 (19.69) 0.55 (21.65) Tightening torque Nm (kgf-m, ft-lb) 98 (10.0, 72.3) 100 (10.2, 73.8) 101 (10.3, 74.5) 102 (10.4, 75.2)
AT-00200
A Measured value
2) Using a press, press-fit the new roller bearing into the specified position. CAUTION: Damage may result if too much force is applied to the roller bearing.
(A)
ST1 498937110 ST2 499787700 ST3 499787500
HOLDER WRENCH ADAPTER
NOTE: Attach ST2 to torque wrench as straight as possible.

ST3
(B)
ST2 L1 [m (in)] L2 [m (in)] AT-00201 ST1 AT-00202
(A) Drive pinion shaft (B) Roller bearing
3) After applying ATF to a new O-ring and attaching it to the drive pinion shaft, attach the drive pinion collar to the drive pinion shaft. 4) Install the lock washer to drive pinion shaft in the proper direction.
6) Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing. Starting torque: 7.6 38.1 N (0.775 3.88 kgf, 1.7 8.6 lb)
AT-00203
7) Crimp the locknut in 2 locations.
4AT-91

8) Measure the dimension B of the drive pinion shaft. ST 398643600 GAUGE
F: ADJUSTMENT
1) Remove the liquid gasket from the mating surface completely. 2) Install the oil pump housing assembly to the converter case, and secure them by tightening the four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing.
B AT-00204
B Measured value
9) Calculate the thickness t mm (in) of the drive pinion shim. t = 6.5r0.0625 (0.256r0.0025) (B A) 10) Select three or less shims from following table.
Part No. 31451AA050 31451AA060 31451AA070 31451AA080 31451AA090 31451AA100 Drive pinion shim Thickness mm (in) 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108)
AT-00205
3) Rotate the drive pinion a few times using ST1 and ST2. ST1 498937110 HOLDER ST2 499787700 WRENCH
ST2
E: INSPECTION
Make sure that all component parts are free of scratches, holes and other faults. Adjust the tooth alignment. <Ref. to 4AT-92, ADJUSTMENT, Drive Pinion Shaft Assembly.>
ST1
AT-00206
4) Adjust the drive pinion and hypoid driven gear backlash. <Ref. to 4AT-99, ADJUSTMENT, Front Differential Assembly.>
4AT-92

5) Apply lead-free red dye evenly on the surface of three to four teeth of the hypoid driven gear. Rotate the drive pinion back and forward several times. Remove the oil pump housing, and check the teeth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. <Ref. to 4AT-99, ADJUSTMENT, Front Differential Assembly.> Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)
(A)
Flank contact Check item: Backlash is too small. Contact pattern
AT-00209
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
(B)
MT-01401
(A) Toe side (B) Heel side
Face contact Check item: Backlash is too large. Contact pattern
AT-00213
AT-00208
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
AT-00212
4AT-93

Toe contact (inside contact) Check item: Contact area is too small. Contact pattern
Heel contact (outside end contact) Check item: Contact area is too small. Contact pattern
AT-00210
AT-00211
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear side.
Corrective action: Increase thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear.
AT-00213
AT-00212
6) If tooth contact is correct, mark the differential side retainer position and loosen. After fitting a new O-ring and oil seal, screw in the differential side retainer to the marked position. Tighten the lock plate with specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-00214
(A) Lock plate
4AT-94
Front Differential Assembly

33.Front Differential Assembly

A: REMOVAL
B: INSTALLATION
1) Install the front differential assembly to the case. NOTE: Be careful not to damage the inside of the converter case (especially the mating surface of the differential side retainer).
(A)
AT-00215
(A) Front differential ASSY

AT-00114
4) Lift up the lever on the rear side of transmission harness connector, and then remove it from the stay. 5) Remove the inhibitor switch connector from the stay. 6) Remove the oil charge pipe. <Ref. to 4AT-66, REMOVAL, Oil Charge Pipe.> 7) Remove the ATF inlet and outlet pipes. <Ref. to 4AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 8) Separate the converter case from the transmission case. <Ref. to 4AT-80, REMOVAL, Converter Case.> 9) Remove the seal pipe. 10) Remove the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER NOTE: ST WRENCH ASSEMBLY (499787000) can also be used. Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case. 11) Remove the front differential assembly while being careful not to damage the attachment part of the retainer.
2) Install the O-ring to left and right side differential retainers. 3) Install the differential side retainers using ST. <Ref. to 4AT-99, ADJUSTMENT, Front Differential Assembly.> ST 18630AA010 WRENCH COMPL RETAINER NOTE: ST WRENCH ASSEMBLY (499787000) can also be used. 4) Adjust the backlash of the front differential. <Ref. to 4AT-99, ADJUSTMENT, Front Differential Assembly.> 5) Install the lock plate. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-00214
(A) Lock plate
4AT-95

6) Install new seal pipe to converter case.
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
AT-00176
1) Remove the taper roller bearing using the ST and the press. ST 498077000 REMOVER
(A) Seal pipe
7) Install the converter case to the transmission case. <Ref. to 4AT-81, INSTALLATION, Converter Case.> 8) Insert the inhibitor switch connector and transmission harness connector onto the stay.
(B) (A)
AT-00216
2) Secure the case in a vise, remove the hypoid driven gear tightening bolts, and then separate the hypoid driven gear into differential case (RH) and differential case (LH).
AT-01351 (A)
(B) (C)
9) Install the ATF cooler pipe. <Ref. to 4AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 10) Install the oil charge pipe together with an Oring. <Ref. to 4AT-66, INSTALLATION, Oil Charge Pipe.> 11) Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion. Normal protrusion A: 50 55 mm (1.97 2.17 in)
AT-00217
(A) Hypoid driven gear (B) Differential case (RH) (C) Differential case (LH)
AT-03204
A Measured value
4AT-96

3) Pull out the straight pin and pinion shaft, then remove the differential bevel gear, washer and differential bevel pinion.
3) Remove the split pin, and then remove the claw. ST 398527700 PULLER ASSY
(A)
AT-00221 AT-00218
(A) Differential case (RH)
2. SIDE RETAINER
NOTE: After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-ring. 1) Remove the O-ring.
(A) Claw (B) Split pin (C) Pin
4) Attach the two claws to the outer race, and set the ST on the differential side retainer. ST 398527700 PULLER ASSY
AT-00222 AT-00219
2) Remove the oil seal.
(A) Shaft (B) Claw
5) Restore the removed claws to original position, and install the pin and split pin.
AT-00220
4AT-97

6) Hold the shaft of ST to avoid detachment from the differential side retainer, and remove the bearing outer race. ST 398527700 PULLER ASSY NOTE: Replace the bearing inner and outer races as a single unit.
4) Install the hypoid driven gear and secure by tightening the bolt. Tightening torque: 62 Nm (6.3 kgf-m, 45.7 ft-lb)
(A)
(B) (C)
AT-00217
AT-00223
(A) Shaft (B) Side retainer
D: ASSEMBLY
1) Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft. 2) Attach the straight pin in the reverse direction.
5) Measurement of backlash (Selection of washer) (1) Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft (2) Measure the gear backlash using ST1 and ST2, and then insert the ST2 though the access window of case. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE NOTE: Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. Fix the differential bevel pinion gear in place with a screwdriver covered with cloth or similar tool when measuring.
(A)
AT-00218
Standard: 0.13 0.18 mm (0.0051 0.0071 in)

ST1
3) Install the washer and differential bevel gear to differential case (LH). Put the differential case (RH) on the case, and assemble two cases.
ST2 AT-00224
4AT-98

(3) If the backlash is out of specification, select a washer from the table below.
Washer Part No. 803038021 803038022 803038023 Thickness mm (in) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)
E: INSPECTION
Check each component for scratches, damage or other faults. Measure the backlash, and then adjust it to be within specification. <Ref. to 4AT-99, ADJUSTMENT, Front Differential Assembly.>
F: ADJUSTMENT
1) Using the ST, screw-in the differential side retainer until resistance is felt. ST 18630AA010 WRENCH COMPL RETAINER NOTE: Screw-in the RH side slightly deeper than the LH side. ST WRENCH ASSEMBLY (499787000) can also be used.
6) Using the ST, install the taper roller bearing. ST 398487700 INSTALLER
ST AT-04377
(A) Taper roller bearing
2. SIDE RETAINER
1) Install the bearing outer race to the differential side retainer. 2) Install a new oil seal using the ST and a hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
ST AT-00227
2) Remove the oil pump housing. 3) Remove the liquid gasket from the mating surface completely. 4) Install the oil pump housing assembly to the converter case, and secure them by tightening the four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
AT-00226
3) Apply gear oil to a new O-ring and install.
AT-00205
AT-00219
4AT-99

5) Rotate the drive pinion a few times using ST1 and ST2. ST1 498937110 HOLDER ST2 499787700 WRENCH
ST2
ST1
7) After reaching the zero state, loosen the LH differential side retainer by 3 notches and secure it with the lock plate. Then after returning the RH differential side retainer, retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the RH differential side retainer further by 1-3/4 notches. This sets the preload. Finally, secure the differential side retainer with the lock plate.
(A)
AT-00206
6) Tighten the LH differential side retainer by rotating the shaft until resistance is felt. Then loosen the RH side differential side retainer. Tighten the LH differential side retainer until the pinion shaft no longer turns, and continue to loosen the RH side. This is the zero state.
AT-00214
(A) Lock plate
NOTE: Turning the differential side retainer by one notch changes the backlash approx. 0.05 mm (0.0020 in).
0.05 mm (0.0020 in)
(A) AT-00229
(A) Differential side retainer

AT-00230
8) Install the Subaru genuine axle shafts to the right and left sides of the front differential. Install the axle shaft to both sides of the front differential section. Part No. 38415AA000 Axle shaft
4AT-100

9) Turn the drive pinion several times using ST1, and check to see if the backlash is within the specification using ST2, ST3, ST4 and ST5. ST1 499787700 WRENCH ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE ST4 499787500 ADAPTER ST5 498255400 PLATE Backlash: 0.13 0.18 mm (0.0051 0.0071 in)
ST1 ST4
ST5
ST2 ST3 AT-00231
10) Adjust the teeth contact of the front differential and drive pinion shaft. <Ref. to 4AT-92, ADJUSTMENT, Drive Pinion Shaft Assembly.>
4AT-101
AT Main Case
34.AT Main Case

A: REMOVAL
12) Take out the high clutch hub and thrust bearing.
(A)
(B)
AT-00233
(A) High clutch hub (B) Thrust needle bearing
13) Take out the front sun gear and thrust needle bearing.
(A) AT-00114
4) Lift up the lever on the rear side of transmission harness connector, and then disconnect it from the stay. 5) Disconnect the inhibitor switch connector from the stay. 6) Disconnect the air breather hose. 7) Remove the oil charge pipe. <Ref. to 4AT-66, REMOVAL, Oil Charge Pipe.> 8) Remove the ATF inlet and outlet pipes. <Ref. to 4AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 9) Separate the converter case from the transmission case. <Ref. to 4AT-80, REMOVAL, Converter Case.> 10) Remove the oil pump housing. <Ref. to 4AT-83, REMOVAL, Oil Pump Housing.> 11) Take out the high clutch, thrust needle bearing and reverse clutch assembly.
(A) (B)
(B)
AT-00251
(A) Front sun gear (B) Thrust needle bearing
14) Pull out while being careful not to break the leaf spring of the 2-4 brake.
(A)
(B) AT-00252
(A) Leaf spring (B) Retaining plate

AT-00232
(A) High clutch and reverse clutch ASSY (B) Thrust needle bearing
4AT-102
AT Main Case
15) Remove the snap ring and thrust needle bearing.

(A) (B)
19) Remove the snap ring.

(A) (B)
AT-00285 AT-00253
(A) Snap ring (B) Thrust needle bearing
(A) Snap ring (B) 2-4 brake piston
20) Take out the 2-4 brake spring retainer. 16) Take out the retaining plate, drive plate and driven plate of the 2-4 brake.
AT-00286 AT-00254
17) Take out the thrust needle bearing, planetary gear assembly and low clutch assembly.
21) Remove the 2-4 brake piston and 2-4 brake piston retainer while taking care not to damage them.
(A)
(B)
AT-00287 AT-00255
18) Remove the 2-4 brake seal.
(A) 2-4 brake piston (B) 2-4 brake piston retainer
AT-04848
4AT-103
AT Main Case
22) Pull out the leaf spring of the low & reverse brake while being careful not to bend it.
(A)
26) Remove the spring retainer.
AT-00302 AT-00293
27) Take out the return spring.
(A) Leaf spring

(A)
AT-00301
28) Apply compressed air.

AT-00294
(A) Snap ring
24) Take out the retaining plate, drive plate, driven plate and dish plate of the low & reverse brake.
AT-04782
29) Take out the low & reverse brake piston.
AT-00295
25) Turn the transmission case upside down, and then take out the socket bolts while holding the one-way clutch inner race by hand.
AT-00300
AT-00296
4AT-104
AT Main Case
B: INSTALLATION
1) Install the low & reverse brake piston. NOTE: Take care not to damage the lip seal. Apply ATF to the lip.
6) Place the front side of transmission body up. 7) Install the thrust needle bearing. 8) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. 9) Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point. 10) Scale and record the weight Z of the flat board that will be placed on the retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 8.5 kgf (18.7 lb). 11) Put the flat board on retaining plate.
AT-00300
2) Install the return spring.
AT-00301
AT-01720
3) Install the spring retainer.
12) Using the following formula, read the push/pull gauge, and calculate N. N = 83 N (8.5 kgf, 18.7 lb) Z N: Value indicated on push/pull gauge 83 N (8.5 kgf, 18.7 lb) : Load applied to clutch plate Z: Flat board weight
AT-00302
4) Install the one-way clutch inner race. 5) Tighten the socket head bolts evenly from the rear side of transmission case. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-00296
4AT-105
AT Main Case
13) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height A. Measure at three or more locations spaced by equal distances and take the average value. NOTE: If measuring in three locations, measure every 120. If measuring in four locations, measure every 90.
14) Installation of the low & reverse brake: Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with a snap ring. NOTE: Pay attention to the orientation of the dish plate.
(A)
AT-00294
(A) Snap ring
15) Apply compressed air intermittently to check for operation.

A (D)
(B) (C) (A)
AT-01721
AT-04782
A Measured value (A) (B) (C) (D) Dish plate Drive plate Driven plate Retaining plate
16) Place same thickness shims on both sides to prevent plate from tilting, then measure and record the clearance B. NOTE: Do not push in the shim down with force to a point where the waves on the drive plate will be crushed.
B
AT-02216
B Measured value
4AT-106
AT Main Case
17) Piston stroke calculation Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new part and adjust it within the initial specification. T=A+B T: Piston stroke A: Amount of drive plate compression B: Clearance between retaining plate and snap ring Initial standard: 2.15 2.65 mm (0.085 0.104 in) Limit thickness: 2.95 mm (0.116 in)
Part No. 31667AA420 31667AA320 31667AA330 31667AA340 31667AA350 31667AA360 31667AA370 31667AA380 Retaining plate Thickness mm (in) 3.8 (0.150) 4.1 (0.161) 4.4 (0.173) 4.7 (0.185) 5.0 (0.197) 5.3 (0.209) 5.6 (0.220) 5.9 (0.232)
19) Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of the 2-4 brake retainer with the hole on the transmission case.
(A)
(B)
AT-00287
20) Install the 2-4 brake piston spring retainer to the transmission case.
18) Install the leaf spring of the low & reverse brake.
(A) AT-00286
21) Position the snap ring in the transmission. Using ST, press the snap ring into the specified location. ST 498677100 COMPRESSOR
ST
AT-00293
(A) Leaf spring
AT-00289
4AT-107
AT Main Case
22) Install the planetary gear and low clutch assembly to the transmission case. NOTE: When installing the low clutch and planetary gear assembly while rotating them, rotate them slowly and pay attention not to damage the seal ring.
(6) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height A. Measure at three or more locations spaced by equal distances and take the average value. NOTE: If measuring in three locations, measure every 120. If measuring in four locations, measure every 90.
AT-00255
23) Measure the amount of drive plate compression and record that value. (1) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. (2) Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point. (3) Scale and record the weight Z of the flat board that will be placed on the retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 10.2 kgf (22.5 lb). (4) Put the flat board on retaining plate.
A (C) (B) (A)
AT-01723
A Measured value (A) Driven plate (B) Drive plate (C) Retaining plate
24) Install pressure plate, drive plate of 2-4 brake, driven plate, retaining plate, and snap ring.
AT-01720
(5) Using the following formula, read the push/ pull gauge, and calculate N. N = 100 N (10.2 kgf, 22.5 lb) Z N: Value indicated on push/pull gauge 100 N (10.2 kgf, 22.5 lb) : Load applied to clutch plate Z: Flat board weight
AT-00254
4AT-108
AT Main Case
25) Install a new 2-4 brake oil seal to the transmission case.
27) Check the piston stroke. (1) Measure clearance B between the retaining plate and snap ring. At this time, do not press down the retaining plate.
B
AT-04848
26) After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
AT-01724
B Measured value
AT-00290
(2) Piston stroke calculation Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new part and adjust it within the initial specification. T=A+B T: Piston stroke A: Amount of drive plate compression B: Clearance between retaining plate and snap ring Initial standard: 1.7 2.1 mm (0.067 0.083 in) Limit thickness: 2.3 mm (0.091 in)
Part No. 31567AA991 31567AB001 31567AB011 31567AB021 31567AB031 31567AB041 Retaining plate Thickness mm (in) 5.6 (0.220) 5.8 (0.228) 6.0 (0.236) 6.2 (0.244) 6.4 (0.252) 6.6 (0.260)
4AT-109
AT Main Case
28) Be careful not to mistake the location of the leaf spring to be installed.
(A)
31) Apply vaseline, and attach the thrust needle bearing to the high clutch hub, then engage the splines of the front planetary carrier correctly to install the high clutch hub. 32) Install the thrust needle bearing in the correct direction.
(C) (E) (D)
(B) AT-00252
(B)
(A) Leaf spring (B) Retaining plate
(A) AT-02219
29) Install the thrust needle bearing in the correct direction.

(A) (C) (E) (D)
(A) (B) (C) (D) (E)
High clutch hub Thrust needle bearing Upside Downside Outside
(B)
33) Install the high clutch assembly and reverse clutch assembly.
(A)
AT-02217
(A) Snap ring (B) (C) (D) (E) Thrust needle bearing Upside Downside Outside
AT-00235
30) Install the front sun gear and the thrust needle bearing.
(A) (C) (E) (D)
(A) High clutch and reverse clutch ASSY
34) Adjust the total end play. <Ref. to 4AT-88, ADJUSTMENT, Oil Pump Housing.>
(B)
AT-02218
(A) Front sun gear (B) (C) (D) (E) Thrust needle bearing Upside Downside Outside
4AT-110
AT Main Case

(A) (C) (B) (D) (E)
AT-02220
(A) (B) (C) (D) (E)
High clutch and reverse clutch ASSY Thrust needle bearing Upside Downside Outside
AT-03204
A Measured value
36) Install a new gasket along with the oil pump housing assembly. <Ref. to 4AT-84, INSTALLATION, Oil Pump Housing.> 37) Install the converter case to the transmission case assembly. <Ref. to 4AT-81, INSTALLATION, Converter Case.> 38) Insert the inhibitor switch connector and transmission harness connector onto the stay.
(B) (A)
AT-01351
39) Install the air breather hose. <Ref. to 4AT-65, INSTALLATION, Air Breather Hose.> 40) Install the ATF cooler pipe. <Ref. to 4AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 41) Install the oil charge pipe together with an Oring. <Ref. to 4AT-66, INSTALLATION, Oil Charge Pipe.>
4AT-111
AT Main Case
C: DISASSEMBLY
1) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
(A)
4) Take out the clutch cover, spring retainer, high clutch piston and reverse clutch piston.
(A) (B)
(C)
AT-00239
AT-00236
(A) Reverse clutch piston (B) Clutch cover (C) Return spring
(A) Snap ring
2) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
(A)
5) Remove the seal ring and lip seal from the high clutch piston and reverse clutch piston.
(A)
(B)
AT-00240 AT-00237
(A) Snap ring
(A) High clutch piston (B) Reverse clutch piston
3) Using the ST1 and ST2, remove the snap ring. ST1 398673600 COMPRESSOR ST2 498627100 SEAT
ST1 (A)
ST2
AT-00238
(A) Snap ring
4AT-112
AT Main Case
2. PLANETARY GEAR AND LOW CLUTCH

1) Remove the snap ring from low clutch drum.
4) Take out the rear planetary carrier, washer and thrust needle bearing.
(A)
(A)
(B)
(B)
AT-00259
AT-00262
(A) Snap ring (B) Low clutch drum
(A) Rear planetary carrier (B) Low clutch drum
2) Take out the front planetary carrier.
5) Take out the rear internal gear.

(A)
(A)
(B) (B) AT-00263
AT-00260
(A) Front planetary carrier (B) Low clutch drum
(A) Rear internal gear (B) Low clutch drum
3) Take out the rear sun gear.

(A)
6) Remove the snap ring from low clutch drum.

(A)
(B) (B) AT-00264
AT-00261
(A) Rear sun gear (B) Rear planetary carrier
4AT-113
AT Main Case
7) Compress the spring retainer of the low & reverse brake, and remove the snap ring from the low clutch drum using ST1 and ST2. ST1 498627100 SEAT ST2 398673600 COMPRESSOR
ST2
12) Remove the needle bearing after taking out the snap ring.
(B) (A)
ST1
AT-00268 (A) (B) AT-00265
(A) Needle bearing (B) Snap ring
3. 2-4 BRAKE
Separate the 2-4 brake piston and piston retainer.
(A) (B)
8) Remove the one-way clutch. <Ref. to 4AT-102, REMOVAL, AT Main Case.> 9) Install the one-way clutch inner race to the low clutch drum, and then apply compressed air to remove the low clutch piston.
(A) (B)
AT-00288
4. ONE-WAY CLUTCH INNER RACE

AT-00266

(A)
(A) Apply compressed air. (B) One-way clutch inner race
10) Remove the one-way clutch inner race. 11) Remove the one-way clutch after taking out the snap ring.
(A) (C)
(B) (B)
AT-00298
(A) One-way clutch inner race (B) Seal ring
AT-00267
2) Remove the needle bearing using ST. ST 398527700 PULLER ASSY
(A) Snap ring (B) Plate (C) One-way clutch
4AT-114
AT Main Case
5. ONE-WAY CLUTCH OUTER RACE

1) Remove the one-way clutch after taking out the snap ring.
(A) (C)
D: ASSEMBLY
1) Install a new seal ring and lip seal to the high clutch piston and reverse clutch piston. 2) Install the high clutch piston to the reverse clutch piston. NOTE: Take care not to damage the seal ring and lip seal.
(B)
(A) AT-00267
(A) Snap ring (B) Plate (C) One-way clutch
(B)
2) Remove the needle bearing after taking out the snap ring.
(B) (A)
AT-00240
(A) High clutch piston (B) Reverse clutch piston
3) Install the reverse clutch piston to the high clutch drum. Align the groove on reverse clutch piston with the groove on high clutch drum during installation.
(A) AT-00268

(B) AT-00241
(A) Reverse clutch piston (B) High clutch drum
4AT-115
AT Main Case
4) Install the spring retainer to the high clutch piston.

(A)
8) Measure the amount of drive plate compression and record that value. (1) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. (2) Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point. (3) Scale and record the weight Z of the flat board that will be placed on the retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 25.5 kgf (56.2 lb). (4) Put the flat board on retaining plate.
(B) AT-00242
(A) Spring retainer (B) High clutch drum
5) Attach the ST to the high clutch piston. ST 498437000 HIGH CLUTCH PISTON GUIDE
ST
AT-00243
AT-01720
6) Install the cover to the high clutch piston while making sure not to bend the high clutch piston seal. 7) Install the snap ring using ST1 and ST2. ST1 398673600 COMPRESSOR ST2 498627100 SEAT ST3 498437000 HIGH CLUTCH PISTON GUIDE
ST1 ST3
(5) Using the following formula, read the push/ pull gauge, and calculate N. N = 250 N (25.5 kgf, 56.2 lb) Z N: Value indicated on push/pull gauge 250 N (25.5 kgf, 56.2 lb) : Load applied to clutch plate Z: Flat board weight
ST2 AT-00244
4AT-116
AT Main Case
(6) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height A. Measure at three or more locations spaced by equal distances and take the average value. NOTE: If measuring in three locations, measure every 120. If measuring in four locations, measure every 90.
11) Apply compressed air intermittently to check for operation.
AT-00246
12) Check the piston stroke. (1) Measure clearance B between the retaining plate and snap ring. (High clutch) At this time, do not press down the retaining plate.
B (A)
(C) (B) (A) AT-01726
B Measured value
AT-01725
(A) Thickness gauge
9) Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
AT-00245
10) Install the snap ring to high clutch drum.
4AT-117
AT Main Case
High clutch retaining plate Part No. Thickness mm (in) 31567AA710 4.7 (0.185) 31567AA720 4.8 (0.189) 31567AA730 4.9 (0.193) 31567AA740 5.0 (0.197) 31567AA670 5.1 (0.201) 31567AA680 5.2 (0.205) 31567AA690 5.3 (0.209) 31567AA700 5.4 (0.213)
(5) Using the following formula, read the push/ pull gauge, and calculate N. N = 150 N (15.3 kgf, 33.7 lb) Z N: Value indicated on push/pull gauge 150 N (15.3 kgf, 33.7 lb) : Load applied to clutch plate Z: Flat board weight (6) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height A. Measure at three or more locations spaced by equal distances and take the average value. NOTE: If measuring in three locations, measure every 120. If measuring in four locations, measure every 90.
13) Choose reverse clutch retaining plate. (1) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. (2) Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point. (3) Scale and record the weight Z of the flat board that will be placed on the retaining plate. NOTE: Use a stiff board which does not bend against load as a flat board to be put on retaining plate. Use a flat board weighing less than 15.3 kgf (33.7 lb). (4) Put the flat board on retaining plate.
(C) (B) (A)
AT-01727
AT-01720
4AT-118
AT Main Case
(7) Install the driven plate, drive plate, retaining plate and snap ring.
Reverse clutch retaining plate Part No. Thickness mm (in) 31567AA910 4.0 (0.157) 31567AA920 4.2 (0.165) 31567AA930 4.4 (0.173) 31567AA940 4.6 (0.181) 31567AA950 4.8 (0.189) 31567AA960 5.0 (0.197) 31567AA970 5.2 (0.205) 31567AA980 5.4 (0.213)
AT-00247
(8) Apply compressed air intermittently to check for operation.
AT-00248
(9) Measure and record the clearance B between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down the retaining plate.
(A) B
AT-01728
B Measured value (A) Thickness gauge
4AT-119
AT Main Case

1) Apply ATF to a new D-ring, and install it to the low clutch piston. 2) Install the low clutch piston to low clutch drum. NOTE: Be careful not to damage the D-ring.
(A)
5) Using ST1, ST2 and ST3, set the cover on the piston and press against it, and attach the snap ring. At this time, be careful not to bend the cover seal. ST1 498627100 SEAT ST2 398673600 COMPRESSOR ST3 498437100 LOW CLUTCH PISTON GUIDE
ST2 ST3
(B) AT-00269
ST1
(A) Low clutch piston (B) Low clutch drum
AT-00272
3) Install the spring retainer to low clutch piston.

(A)
6) Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with a snap ring.
(A) (C)
(D)
(B) AT-00270
(B) AT-02221
(A) Spring retainer (B) Low clutch drum
4) Attach the ST to the low clutch drum. ST 498437100 LOW CLUTCH PISTON GUIDE
(A) (B) (C) (D)
Snap ring Low clutch drum Dish plate Low clutch piston side
ST
7) Check the low clutch for operation. (1) Remove the one-way clutch. <Ref. to 4AT102, REMOVAL, AT Main Case.> (2) Set the one-way clutch inner race, and apply compressed air for checking.
(A)
AT-00271 (B)
AT-00274
(A) Apply compressed air. (B) Low clutch drum
4AT-120
AT Main Case
8) Check the low clutch clearance. (1) Place same thickness shims on both sides to prevent plate from tilting. (2) Check the clearance between retaining plate and low clutch operation. Initial standard: 0.7 1.1 mm (0.028 0.043 in) Limit thickness: 1.6 mm (0.063 in)
(A)
10) Install the rear internal gear.

(A)
(B) AT-00276
(A) Rear internal gear (B) Low clutch drum

(B) AT-00283 (A) (C) (D) (B)
(A) Thickness gauge (B) Low clutch drum
If the clearance exceeds the service limits, replace the drive plate, then select and adjust the retaining plate so that the clearance is within default standard values.
Part No. 31567AB050 31567AB060 31567AB070 31567AB080 31567AB090 Retaining plate Thickness mm (in) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) (A) Thrust needle bearing (B) Low clutch drum (C) Rear planetary carrier side (D) Low clutch piston side
AT-02222
12) Install the washer by aligning the protrusion of the washer with the hole of the rear planetary carrier.
(A)
9) Install the washer to the rear internal gear.

(A) (B)
(B)
AT-00278 AT-00275
(A) Rear internal gear (B) Washer
(A) Washer (B) Rear planetary carrier
4AT-121
AT Main Case
13) Install the rear planetary carrier to the low clutch drum.
(A)
(A) (C)
(B) (B) AT-00262
(D)
AT-00280
(A) Rear planetary carrier (B) Low clutch drum

(A) (B)
(A) (B) (C) (D)
Thrust needle bearing Front planetary carrier Rear sun gear side Front planetary carrier side
17) Install the front planetary carrier to the low clutch drum.
(A)
AT-02223
(B)
(A) Rear sun gear side (B) Rear planetary carrier side (A) Front planetary carrier (B) Low clutch drum
AT-00260
15) Install the rear sun gear in the correct direction.

(A)
18) Install the snap ring to the low clutch drum.
(A) (B) (B) AT-00261
(A) Rear sun gear (B) Rear planetary carrier (A) Snap ring (B) Front planetary carrier
AT-00281
4AT-122
AT Main Case
19) Install the needle bearing, and then secure with the snap ring.
(B) (A)
4. ONE-WAY CLUTCH INNER RACE

1) Install the needle bearing to inner race using ST and a press. ST 398497701 SEAT
ST
AT-00268
AT-00299
20) Install the one-way clutch and one-way clutch inner race, then secure with the snap ring. 21) Set the inner race. Make sure that the clutch locks in the clockwise direction and rotates freely in the counterclockwise direction.
2) Apply vaseline to the groove of the inner race and to the new seal ring. 3) Install two seal rings to the one-way clutch inner race.
(A)
(A) (B)
(B)
AT-00298
AT-00282
(A) One-way clutch inner race (B) Seal ring
(A) Lock (B) Free
3. 2-4 BRAKE
1) Apply ATF to the new D-ring, then install to the 24 brake piston. 2) Install 2-4 brake piston to 2-4 brake piston retainer. NOTE: Do not damage the D-ring.
(A) (B)
AT-00288
4AT-123
AT Main Case
5. ONE-WAY CLUTCH OUTER RACE

1) Install the needle bearing, and then secure with the snap ring.
(B) (A)
E: INSPECTION
Check the following items. Drive plate facing for wear or damage Driven plate for discoloration (burned color) Snap ring wear and spring retainer deformation Wear and damage of the lip seal and D-ring Piston and piston check ball operation Adjust the total end play. <Ref. to 4AT-88, ADJUSTMENT, Oil Pump Housing.>

AT-00268
2) Install the one-way clutch and one-way clutch inner race, then secure with the snap ring. 3) Set the inner race. Make sure that the clutch locks in the clockwise direction and rotates freely in the counterclockwise direction.
Check the following items. Drive plate facing for wear or damage Driven plate for discoloration (burned color) Snap ring wear and spring retainer deformation Wear and damage of the lip seal and D-ring Measure the total end play and adjust it to be within specifications. <Ref. to 4AT-88, ADJUSTMENT, Oil Pump Housing.>
3. 2-4 BRAKE
Check the following items. Drive plate facing for wear or damage Driven plate for discoloration (burned color) Snap ring wear, leaf spring setting and breakage, and spring retainer deformation Wear and damage of the lip seal and D-ring Measure the total end play and adjust it to be within specifications. <Ref. to 4AT-88, ADJUSTMENT, Oil Pump Housing.>
(A) (B)
AT-00282
4. ONE-WAY CLUTCH
Check that the snap ring is not damaged and the seal ring is not deformed. Measure the total end play and adjust it to be within specifications. <Ref. to 4AT-88, ADJUSTMENT, Oil Pump Housing.>
(A) Lock (B) Free
5. LOW & REVERSE BRAKE

Check the following items. Drive plate facing for wear or damage Driven plate for discoloration (burned color) Snap ring wear, leaf spring setting and breakage, and spring retainer deformation Lip seal wear and damage
4AT-124
Transmission Control Device

35.Transmission Control Device

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 4AT-35, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter clutch assembly. <Ref. to 4AT-67, REMOVAL, Torque Converter Clutch Assembly.> 3) Remove the input shaft. 4) Lift up the lever on the rear side of transmission harness connector, and then remove it from the stay. 5) Disconnect the air breather hose. <Ref. to 4AT65, REMOVAL, Air Breather Hose.> 6) Remove the inhibitor switch connector from the stay. 7) Wrap vinyl tape around the nipple attached to the air breather hose. 8) Remove the pitching stopper bracket. 9) Remove the inhibitor switch. <Ref. to 4AT-47, REMOVAL, Inhibitor Switch.> 10) Remove the control valve body assembly. <Ref. to 4AT-56, REMOVAL, Control Valve Body.> 11) Pull out the straight pin of manual plate.
12) Remove the bolts securing select lever, and then remove the select lever, manual plate and parking rod. NOTE: Be careful not to damage the lips of press-fitted oil seal in the case.
(A)
(C) (D) (B)
AT-04845
(A) (B) (C) (D)
Bolt Range select lever Manual plate Parking rod
13) Remove the detent spring.
AT-04846 AT-04847
4AT-125

B: INSTALLATION
1) Install the detent spring to the transmission case. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
4) Insert a new straight pin to manual plate.
AT-04847
AT-04846
2) Insert the range select lever, and tighten the bolts. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
5) Install the oil pan and the control valve assembly. <Ref. to 4AT-57, INSTALLATION, Control Valve Body.> 6) Turn over the transmission case to its original position. 7) Install the pitching stopper bracket. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb) 8) Install and adjust the inhibitor switch. <Ref. to 4AT-46, Inhibitor Switch.> 9) Insert the inhibitor switch connector and transmission harness connector onto the stay.
(B) (A)
AT-04849
3) Insert the manual plate and parking rod.

(A) AT-01351
(C) (D) (B)
10) Install the air breather hose. <Ref. to 4AT-65, INSTALLATION, Air Breather Hose.>
AT-04845
(A) (B) (C) (D)
4AT-126

AT-03204
A Measured value
C: INSPECTION
Make sure that the manual lever and detent spring are not worn or otherwise damaged.
4AT-127

4AT-128

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

A: PROCEDURE
1 Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to 4AT(diag)-4, Check List for Interview.> 2) Check the following items which may be affecting the AT trouble. General inspection <Ref. to 4AT(diag)-5, INSPECTION, General Description.> Disconnection of harness connector Visual check for harness damage Oil leakage Stall speed test <Ref. to 4AT-30, Stall Test.> Line pressure test <Ref. to 4AT-33, Line Pressure Test.> Transfer clutch pressure test <Ref. to 4AT-34, Transfer Clutch Pressure Test.> Time lag test <Ref. to 4AT-32, Time Lag Test.> Road test <Ref. to 4AT-29, Road Test.> Inhibitor switch <Ref. to 4AT-46, Inhibitor Switch.> CHECK ATF TEMPERATURE WARNING LIGHT. Start the engine and wait for 2 seconds or more. CHECK ATF TEMPERATURE WARNING LIGHT. 1) Turn the ignition switch to OFF. 2) Check the ATF temperature warning light. <Ref. to 4AT(diag)-24, INSPECTION, AT OIL TEMP Warning Light Display.> 3) Turn the ignition switch to ON and wait for at least 2 seconds. 4) Start the engine. CHECK DTC. Display DTC. NOTE: If the communication function of Subaru Select Monitor cannot be executed normally, check the communication circuit. <Ref. to 4AT(diag)26, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, Diagnostic Procedure for Subaru Select Monitor Communication.> PERFORM GENERAL DIAGNOSTICS. 1) Inspect using Diagnostic Procedure without Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)-83, Diagnostic Procedure without Diagnostic Trouble Code (DTC).> 2) Inspect using General Diagnostic Table. <Ref. to 4AT(diag)-94, General Diagnostic Table.> 3) Perform the Inspection Mode. <Ref. to 4AT(diag)-21, Inspection Mode.> 4) Display DTC. Check Yes Is the item that is thought to Go to step 2. influence the AT problem working properly? No Repair or replace each item.
Is the ATF temperature warning Go to step 4. light blinking? Is the ATF temperature warning Go to step 4. light blinking?
Go to step 3.
Go to step 5.
Is DTC displayed?
Go to step 6. NOTE: Record all DTC.
Go to step 5.
Is DTC displayed?
Go to step 6.
Finish the diagnosis.
4AT(diag)-2

Step Check PERFORM DIAGNOSIS. Is DTC displayed? 1) Inspect using Diagnostic Procedure with Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)-32, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> NOTE: For DTC table, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)-30, List of Diagnostic Trouble Code (DTC).> 2) Repair the trouble cause. 3) Perform the Clear Memory Mode. 4) Perform the Inspection Mode. <Ref. to 4AT(diag)-21, Inspection Mode.> 5) Display DTC. Yes No Inspect using Finish the diagnoDiagnostic Proce- sis. dure with Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)-32, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
4AT(diag)-3


A: CHECK
Customers name Date of purchase Date of repair Transmission model Odometer reading Frequency Weather
Transmission
V.I.N. km (miles)
( Place ( Ambient air temperature Vehicle speed AT warning light (ATF temperature warning light) Select lever position Driving condition
Continuous Intermittent ( times a day) Fine Cloudy Rainy Snowy Others ) Highland Suburbs Inner city Uphill Others ) Hot Warm Cool Cold Blinks continuously P R N Not affected At racing While decelerating ON OFF No up-shift No down-shift No kick down Vehicle does not move ( Any position Lock-up malfunction Noise or vibration Shift shock or slip Select lever does not move Others ) D
Rough road
km/h (MPH) Does not blink SPORT mode At starting When accelerating While turning ( RH/ LH)
While idling While cruising
SPORT mode Symptom
Particular position)
4AT(diag)-4
General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG
The airbag system wiring harness is routed near the TCM. CAUTION: All the airbag system wiring harnesses and connectors are colored yellow. Do not use an electric test equipment to check these circuits. Be careful not to damage the airbag system wiring harness when performing diagnostics or servicing the TCM.
3. ATF LEVEL
Make sure that ATF level is the specified amount. <Ref. to 4AT-26, INSPECTION, Automatic Transmission Fluid.>
(A)
(C) (D)
L F HOT
(B)
(E)
COLD L
(C) (D) AT-04841
2. MEASUREMENT
When measuring the voltage and resistance of the ECM, TCM or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert a pin of more than 0.65 mm (0.026 in) diameter.
(A) (B) (C) (D) (E)
Oil level gauge Inspection position when HOT Upper level Lower level Inspection position when COLD
B: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of the electrolyte. Standard voltage: 12 V or more Specific gravity: 1.260 or more
4. FRONT DIFFERENTIAL OIL LEVEL

Make sure the front differential oil level is the specified amount. <Ref. to 4AT-28, INSPECTION, Differential Gear Oil.>
(A) (A)
(B) (C)
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened securely. Chassis side Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
AT-04863
AT-01464
4AT(diag)-5
General Description
5. OPERATION OF SELECT LEVER

Make sure there is no noise, dragging or contact pattern in each select lever range. WARNING: Stop the engine while checking operation of the select lever.
AT-02048
4AT(diag)-6
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
2. GENERAL TOOL
TOOL NAME Circuit tester Oscilloscope REMARKS Used for measuring resistance, voltage and current. Used for measuring the sensor.
4AT(diag)-7


A: LOCATION
1. CONTROL MODULE
(1)
(5)
(3)
(4)
(2) AT-01873
(1) (2)
Engine control module (ECM) ATF temperature warning light (AT warning light)
(3)
Transmission control module (TCM)
(4) (5)
Data link connector Body integrated unit
4AT(diag)-8

(1)
(2) AT-01874 AT-03759
(4)
(3)
AT-04968
AT-01877
(5)
AT-01876
4AT(diag)-9

2. SENSOR
(3) (6)
(5) (1) (2)
(4) AT-02979
(1) (2) (3)
Accelerator pedal position sensor Front vehicle speed sensor Inhibitor switch
(4) (5)
Rear vehicle speed sensor Torque converter turbine speed sensor
(6)
ATF temperature sensor
4AT(diag)-10

(2)
(4)
(1)
AT-00375
AT-01474
(5)
(3)
AT-04909
AT-00331
(6)
AT-04842
4AT(diag)-11

3. SOLENOID
(7)
(6)
(5)
(1)
(2)
(3)
(4) AT-04844
(1) (2) (3)
Line pressure linear solenoid High clutch duty solenoid 2-4 brake duty solenoid
(4) (5)
Low & reverse duty solenoid Low clutch duty solenoid
(6) (7)
Transfer duty solenoid Lock-up duty solenoid
(2) (3)
(4)
(1)
(7) (6)
(5)
AT-04843
4AT(diag)-12
Transmission Control Module (TCM) I/O Signal

5. Transmission Control Module (TCM) I/O Signal

TO
B55 6 16 15 27 26 35 34
TO
B54
7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28
5 4 3 2 1 14 13 12 11 10 9 8 7 25 24 23 22 21 20 19 18 17 33 32 31 30 29 28
AT-03733
Contents
Backup power supply
ACC power supply Ignition power supply
Check with ignition switch ON. Measured terminal (Connector & Terminal No.) Measuring condition Positive terminal Ground terminal (B55) No. 27 Chassis ground (B55) No. 26 Chassis ground (B55) No. 25 Chassis ground Ignition (B55) No. 12 Chassis ground Switch ACC (B55) No. 1 Chassis ground Ignition Switch ON (B55) No. 2 Chassis ground Select lever P range Select lever Except P range Select lever N range Select lever Except N range Select lever R range Select lever Except R range Select lever D range Select lever Except D range ATF temperature 20C (68F) ATF temperature 80C (176F)
Voltage (V)
Resistance (:)
10 13
10 13 10 13 Less than 1 8 or more Less than 1 8 or more Less than 1 8 or more Less than 1 8 or more 3.5 4.3 1.0 2.2
2.5k 7.0 k 300 800
P range switch
(B54) No. 14
Chassis ground
N range switch Inhibitor switch R range switch
(B54) No. 11
Chassis ground
(B54) No. 13
Chassis ground
D range switch
(B54) No. 10
Chassis ground
ATF temperature sensor
(B54) No. 23
(B54) No. 12
4AT(diag)-13

Check with ignition switch ON. Measured terminal (Connector & Terminal No.) Measuring condition Positive terminal Ground terminal
Contents
Voltage (V)
Resistance (:) Less than 1 (When inserting connector) f (When disconnecting connector) Less than 1 (When inserting connector) f (When disconnecting connector) 450 650
ATF temperature sensor ground
(B54) No. 12
Chassis ground
Rear vehicle speed sensor
(B54) No. 26
(B54) No. 15
20 km/h (12 MPH) Vehicle speed at least
2 or more (AC range)
Rear vehicle speed sensor ground
(B54) No. 15
Chassis ground
Front vehicle speed sensor Front vehicle speed sensor ground Torque converter turbine speed sensor Torque converter turbine speed sensor ground
(B54) No. 27 (B54) No. 16
(B54) No. 16 Chassis ground
Engine idling after warm up (D range) Engine idling after warm up (N range) Ignition switch ON (engine OFF) Engine start Ignition switch ON (with engine OFF) Throttle fully closed in R range after warm up. Ignition switch ON (with engine OFF) Throttle fully closed in R range after warm up. When lock up occurs. When lock up is released. With fuse installed to FWD switch With fuse removed from FWD switch (1st gear) P or N range 2nd or 4th gear 3rd or 4th gear P or N range
0 1 or more (AC range) Less than 1 5 or more (AC range)
(B54) No. 1
(B54) No. 2
450 650
(B54) No. 2
Chassis ground
Engine speed signal
(B55) No. 11
Chassis ground
3.7 7.7 4.0 6.0 1.1 5.1
Line pressure linear solenoid
(B54) No. 4
(B54) No. 3
Line pressure linear solenoid ground
(B54) No. 3
Chassis ground
Less than 1 10.5 or more
Less than 1
Lock-up duty solenoid
(B54) No. 6
Chassis ground
2.0 4.5 Less than 1 Less than 1 2.0 4.5 2.0 3.0 5.0 or more Less than 1 Less than 1 5.0 or more
Transfer duty solenoid
(B54) No. 5
Chassis ground
2-4 brake duty solenoid High clutch duty solenoid
(B55) No. 4 (B55) No. 6
Chassis ground Chassis ground
2.0 4.5 2.0 4.5
4AT(diag)-14

Check with ignition switch ON. Measured terminal (Connector & Terminal No.) Measuring condition Positive terminal Ground terminal 1st or 2nd gear (B55) No. 7 Chassis ground P or N range Except 1 range Driving at 1st gear (B55) No. 5 Chassis ground on manual mode (15 km/h (9.3 MPH) or more) (B55) No. 8 (B54) No. 18 (B54) No. 17 (B55) No. 10 (B55) No. 20 (B55) No. 21 (B55) No. 22 (B55) No. 23 Chassis ground Chassis ground Chassis ground Chassis ground Chassis ground Chassis ground Chassis ground Chassis ground Ignition switch ON Ignition switch ON Fuse removed Fuse installed
Contents
Voltage (V) Less than 1 5.0 or more 5.0 or more 2.5 5.0
Resistance (:)
Low clutch duty solenoid
2.0 4.5
Low & reverse duty solenoid
2.0 4.5
Data link signal (Subaru Select Monitor) CAN communication signal (+) CAN communication signal () FWD switch
Pulse signal Pulse signal 10.5 or more 1 or less 0 0 0 0
Less than 1 Less than 1 Less than 1 Less than 1
System ground circuit
4AT(diag)-15


A: OPERATION
1. READ DIAGNOSTIC TROUBLE CODE (DTC)
1) Prepare the Subaru Select Monitor kit. <Ref. to 4AT(diag)-7, PREPARATION TOOL, General Description.> 2) Prepare PC with Subaru Select Monitor installed. 3) Connect the USB cable between SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 4) Connect the diagnosis cable to SDI. 5) Connect SDI to data link connector located in the lower portion of the instrument panel (on the drivers side).
12) On the Diagnostic Code(s) Display display, select the {Temporary Diagnostic Code(s)} or {Memorized Diagnostic Code(s)}. NOTE: For detailed operation procedure, refer to the PC application help for Subaru Select Monitor. For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)30, List of Diagnostic Trouble Code (DTC).>
AT-04371
CAUTION: Do not connect scan tools other than the Subaru Select Monitor. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 8) On the Main Menu display, select the {Each System Check}. 9) On the System Selection Menu display, select the {Transmission Control System}. 10) After transmission type information pops up, select [OK]. 11) On the Transmission Diagnosis display, select the {Diagnostic Code(s) Display}.
4AT(diag)-16

2. READ CURRENT DATA

1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Transmission Control System}. 3) After transmission type information pops up, select [OK]. 4) On the Transmission Diagnosis display, select the {Current Data Display & Save}. 5) On the Current Data Display & Save display, select the {Normal sampling}. 6) Using the scroll key, scroll the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Battery voltage Rear vehicle speed sensor signal Front vehicle speed sensor signal Engine speed signal Automatic transmission fluid temperature signal Accelerator pedal position sensor Gear position Line pressure control duty ratio Lock up clutch control duty ratio Transfer clutch control duty ratio Accelerator pedal position sensor power supply Torque converter turbine speed signal 2-4 brake timing pressure control duty ratio Low clutch duty ratio High clutch duty ratio Low & reverse brake duty ratio Accelerator position FWD switch signal Stop light switch signal Anti lock brake system signal Parking range signal Neutral range signal Reverse range signal Drive range signal AT diagnosis light output signal Cruise control signal ATF temperature light Up shift signal Down shift signal Sport mode signal Display Battery Voltage Rear Wheel Speed Front Wheel Speed Engine Speed ATF Temp. Throttle Sensor Voltage Gear Position Line Pressure Duty Ratio Lock Up Duty Ratio Transfer Duty Ratio Throttle Sensor Power Turbine Revolution Speed Brake Clutch Duty Ratio Low Clutch Duty High Clutch Duty L&R B Duty Accel. Opening Angle FWD Switch Stop Light Switch ABS Signal P Range N Range R Range Signal D Range Signal Diagnosis Lamp Cruise Control Signal ATF Temperature Lamp Up Switch Down Switch Tiptronic Mode Switch Unit of measure V km/h or MPH km/h or MPH rpm C or F V % % % V rpm % % % % % ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
NOTE: For detailed operation procedure, refer to the PC application help for Subaru Select Monitor.
4AT(diag)-17

3. CLEAR MEMORY MODE

1) Shift the select lever to P range. 2) On the Main Menu display, select the {Each System Check}. 3) On the System Selection Menu display, select the {Transmission Control System}. 4) After transmission type information pops up, select [OK]. 5) On the Transmission Diagnosis display, select the {Clearing Memory}. 6) When Done. Turn ignition switch OFF pops up, select [OK]. 7) Turn Subaru Select Monitor and ignition switch to OFF. To turn the ignition switch to ON again, wait for 10 seconds or more. NOTE: If {Clear Memories 2} is selected and performed, DTC and learned control memory are cleared. If {Clear Memories 2} is performed, perform learning control promotion. <Ref. to 4AT(diag)-18, FACILITATION OF LEARNING CONTROL, OPERATION, Subaru Select Monitor.> For detailed operation procedure, refer to the PC application help for Subaru Select Monitor.
4. FACILITATION OF LEARNING CONTROL

NOTE: Follow the messages displayed on the Subaru Select Monitor when working. When the following work is performed, perform learning control for the transmission. Replacement of TCM/Replacement or disassembly of transmission assembly/Replacement of control valve body/Performing Clear Memories 2 is executed. 1) Warm up or cool down until the ATF temperature displayed on the Subaru Select Monitor is 60 80C (140 176F). 2) Shift the select lever to P range. 3) Fully apply the parking brake. 4) Lift up the vehicle. CAUTION: Be sure to keep the lowest edge of the tires 30 cm or more off the ground because the vehicle vibrates during the work. 5) Connect the Subaru Select Monitor to data link connector. 6) Turn the ignition switch to ON. 7) Turn off all switches causing an electrical load, such as headlights, A/C, seat heater and rear defogger. 8) On vehicles equipped with an ECO switch, turn the ECO switch to ON. On vehicles equipped with an SPORT mode, turn the SPORT mode OFF. On vehicles equipped with an POWER/HOLD switch, turn the POWER/HOLD switch to OFF. On vehicles equipped with SI-DRIVE, set to I mode. NOTE: Error message is not displayed even when an incorrect mode is set. While the operation is continued, AT learning promoting is displayed, but it cannot end normally. If the message does not change after 2 minutes have passed, retry AT learning mode from the beginning. CAUTION: Do not turn the power of the Subaru Select Monitor OFF and do not disconnect the data link connector during the operation. 9) Select {AT related learning/inspection mode} in the Transmission Diagnosis screen of the Subaru Select Monitor. 10) Select {AT learning mode} in the AT related learning/inspection mode screen of the Subaru Select Monitor.
4AT(diag)-18

11) Follow the messages displayed on the Subaru Select Monitor screen when working. NOTE: During AT learning in progress, SPORT indicator light in the combination meter starts flashing at 2 Hz and the learning operation starts. The following message is displayed on the screen when the SPORT indicator light turns off. 12) AT simple learning is complete when the message AT learning normally ended is displayed. NOTE: If a communication error occurs during learning, restart the AT learning mode over from the beginning. If the message Execute AT learning again after fixing troubles of the vehicle is displayed during learning, select [OK] to display the List of Diagnostics Trouble Code. After repairing the locations indicated by the DTC, start the AT learning mode over from the beginning. If the message AT learning ended abnormally is displayed, start the AT learning mode over from the beginning. When communication error occurs during learning, select lever does not shift occasionally. If select lever does not shift, turn the ignition to OFF and operate the lever.
Message AT learning ended abnormally Main cause of abnormal incompletion A malfunction was detected during AT learning The accelerator pedal was pressed during AT learning An unspecified operation was performed during AT learning Brake pedal not stepped on firmly enough. Parking brake not applied strongly enough. Abnormal idle speed increase, etc.
For detailed operation procedure, refer to the PC application help for Subaru Select Monitor.
4AT(diag)-19

7. Read Diagnostic Trouble Code (DTC)

A: OPERATION
Refer to Subaru Select Monitor for information on how to display a DTC. <Ref. to 4AT(diag)-16, OPERATION, Subaru Select Monitor.> For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)30, List of Diagnostic Trouble Code (DTC).>
4AT(diag)-20
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING: Observe the traffic law during driving on roads. 1) Shift the select lever to D range, and then drive the vehicle at 60 km/h (37 MPH) for at least 10 seconds. 2) Drive the vehicle with manual mode.
4AT(diag)-21
Clear Memory Mode

9. Clear Memory Mode

A: OPERATION
Refer to Subaru Select Monitor for information about how to clear a DTC. <Ref. to 4AT(diag)-18, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.>
4AT(diag)-22
AT OIL TEMP Warning Light Display

10.AT OIL TEMP Warning Light Display

A: OPERATION
When any on-board diagnostics item is malfunctioning, the ATF temperature warning light blinks when a malfunction is detected after starting the engine until the ignition switch is turned OFF. The malfunctioning part or unit can be determined by a DTC during the on-board diagnostics operation. Problems which occurred previously can also be identified through the memory function. If the ATF temperature warning light does not show a problem (although a problem is occurring), the problem can be determined by checking the performance characteristics of each sensor using the Subaru Select Monitor. Warning light signal patterns are shown in the figure.
(A) (1)
(2)
(B) (1) (3) (2)
(4) (C) (1) (3) (2) (5) AT-02980
(A) (1) (2)
Ignition switch ON (engine OFF) ON OFF
(B) (3) (4)
Normal (engine ON) 2 seconds 0.25 seconds
(C) (5)
Faulty (engine ON) Blink
Perform the inspection when the ATF temperature warning light does not operate correctly. <Ref. to 4AT(diag)-24, INSPECTION, AT OIL TEMP Warning Light Display.>
4AT(diag)-23

B: INSPECTION
DIAGNOSIS: ATF temperature warning light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), the ATF temperature warning light does not illuminate. WIRING DIAGRAM:
i106 3 i107
No. 5
ATF TEMPERATURE WARNING LIGHT MICRO COMPUTER CAN TRANSCEIVER & RECEIVER COMBINATION METER
1 2 3 4
i10
IGNITION SWITCH
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
WN WN
SBF-6
21
22
MAIN SBF
ON
ON
i10
* *
CAN JOINT CONNECTOR
CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
i106
BATTERY ON ON
i107
WN WN
* *
A:
i84
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 BODY INTEGRATED UNIT B20 B30 B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A27
A26 i84 B: B280
A:
*2 *2
*1 *1
ON : WITHOUT NAVIGATION
WN : WITH NAVIGATION
CAN JOINT CONNECTOR
B365 B54 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
* *1 *2
: TERMINAL No. OPTIONAL ARRANGEMENT : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 11, 12 AND 13 : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 8, 9, 10, 18, 19 AND 20
B54
18
TCM
17
AT-04907
4AT(diag)-24

Step CHECK ATF TEMPERATURE WARNING LIGHT. Turn the ignition switch to ON. CHECK ATF TEMPERATURE WARNING LIGHT. After the ignition switch is ON, wait for 2 seconds or more. CHECK ATF TEMPERATURE WARNING LIGHT. Start the engine. Check Does the ATF temperature warning light illuminate? Does the ATF temperature warning light illuminate? Yes Go to step 2. No Perform the selfdiagnosis of combination meter. Go to step 4.
Go to step 3.
CHECK SUBARU SELECT MONITOR COMMUNICATION. Connect the Subaru Select Monitor to data link connector.
CHECK TCM. Display the current data of TCM using Subaru Select Monitor.
CHECK BODY INTEGRATED UNIT. Display current data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.>
CHECK TCM. Display the current data of TCM using Subaru Select Monitor. <Ref. to 4AT(diag)-16, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Display current data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.>
Normal. Go back to Go to step 7. Basic Diagnostic Procedure. <Ref. to 4AT(diag)-2, Basic Diagnostic Procedure.> Check the power Is the communication between Go to step 5. Subaru Select Monitor and supply ground cirTCM normal? cuit of TCM and Subaru Select Monitor communication. <Ref. to 4AT(diag)-26, Diagnostic Procedure for Subaru Select Monitor Communication.> Is the Diagnosis Light output Go to step 6. Replace the TCM. signal ON? <Ref. to 4AT-61, Transmission Control Module (TCM).> Is the ATF Temperature Lamp Replace the com- Check DTC of input signal on Illuminate? bination meter body integrated assembly. <Ref. to unit. <Ref. to IDI-22, Combina- LAN(diag)-12, tion Meter.> OPERATION, Subaru Select Monitor.> Is the Diagnosis Light output Replace the TCM. Go to step 8. signal ON? <Ref. to 4AT-61, Transmission Control Module (TCM).> Perform the selfIs the ATF Temperature Lamp Check DTC of diagnosis of cominput signal on Illuminate? body integrated bination meter. unit. Perform the diagnosis accord- <Ref. to IDI-5, ing to DTC. <Ref. INSPECTION, Combination Meter to LAN(diag)-12, OPERATION, Sub- System.> aru Select Monitor.>
Does the ATF temperature warning light go off?
4AT(diag)-25


DIAGNOSIS: Defective harness connector TROUBLE SYMPTOM: Subaru Select Monitor communication failure WIRING DIAGRAM:
B40 BATTERY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 MAIN SBF
E
1 2
B11
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 5
SBF-6
No. 13 16 7 DATA LINK CONNECTOR B40
M/B No. 12
IGNITION SWITCH
5 4
B55
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
F/B No. 12
A: B134 ECM C: B136 25 26 27 A5 2 1 8 C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B55
TCM
C6
23
22
20
21
B21 36 E2
A: B134 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
19
20
B11 T4
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 35 43 48 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
CONTROL VALVE BODY
AT-04897
4AT(diag)-26

Step Check Yes CHECK INSTALLATION OF TCM CONNEC- Is TCM connector connected to Go to step 2. TOR. TCM? Turn the ignition switch to OFF. CHECK SUBARU SELECT MONITOR POW- Is the voltage 10 V or more? Go to step 3. ER SUPPLY CIRCUIT. Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 16 (+) Chassis ground (): CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. 1) Disconnect the connectors from ECM. 2) Measure the resistance of harness between data link connector and ECM. Connector & terminal (B40) No. 4 (B136) No. 6: (B40) No. 5 (B136) No. 6: CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. Measure the resistance of harness between data link connector and chassis ground. Connector & terminal (B40) No. 4 Chassis ground: (B40) No. 5 Chassis ground: CHECK ENGINE GROUND CIRCUIT. Check the engine ground circuit. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to transmission system can be executed normally. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM connector. 3) Check whether communication to engine system can be executed normally. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Connect the TCM connector. 3) Disconnect the connectors of TPM control unit, airbag control module, body integrated unit, and ABSCM&H/U. CAUTION: When disconnecting the connector from airbag control module, always follow the precautions on AB section. <Ref. to AB-4, CAUTION, General Description.> 4) Turn the ignition switch to ON. 5) Check whether communication to transmission system can be executed normally. Is the resistance less than 1 :? Go to step 4. No Connect the TCM connector to TCM. Repair harness connector between the battery and data link connector, and poor contact of the connector. Repair the open circuit of harness between data link connector and ECM.
Go to step 5.
Repair the short circuit of harness between data link connector and ground terminals.
5 6
Is the engine ground circuit nor- Go to step 6. mal? Is the name of system disGo to step 11. played on Subaru Select Monitor?
Repair ground circuit of ECM. Go to step 7.
Is the name of system disGo to step 9. played on Subaru Select Monitor?
Go to step 8.
Is the name of system disCheck each control Go to step 9. played on Subaru Select Moni- module. tor?
4AT(diag)-27

Step CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors of TCM, ECM, TPM control unit, airbag control module, body integrated unit, and ABSCM&H/U. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B40) No. 7 Chassis ground: CHECK OUTPUT SIGNAL OF TCM. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM and chassis ground. Connector & terminal (B40) No. 7 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND DATA LINK CONNECTOR. Measure the resistance between TCM connector and data link connector. Connector & terminal (B55) No. 8 (B40) No. 7: CHECK INSTALLATION OF TRANSMISSION HARNESS CONNECTOR. Check Is the resistance 1 M: or more? Yes Go to step 10. No Check harness and connector between each control module and data link connector.
10
11
Check harness Go to step 11. and connector between each control module and data link connector. Is the resistance less than 1 :? Go to step 12. Repair the harness and connector between TCM and data link connector. Is the transmission harness connector connected to bulkhead harness connector? Go to step 13. Connect the bulkhead harness connector to transmission harness connector. Go to step 14.
12
13
14
15
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control module power supply and data link connector? CHECK POWER SUPPLY OF TCM. Is the voltage 10 13 V? 1) Disconnect the connector from TCM. 2) Turn the ignition switch to ON. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 27 (+) Chassis ground (): (B55) No. 26 (+) Chassis ground (): (B55) No. 25 (+) Chassis ground (): CHECK FUSE (NO. 12). Is the fuse (No. 12) blown out? 1) Turn the ignition switch to OFF. 2) Remove the fuse (M/B No. 12).
Repair the poor contact. Go to step 16.
Go to step 15.
16
CHECK IGNITION POWER SUPPLY CIRIs the voltage 10 13 V? CUIT. 1) Turn the ignition switch to ON (engine OFF). 2) Measure the ignition power supply voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 1 (+) Chassis ground (): (B55) No. 2 (+) Chassis ground ():
Replace the fuse (No. 12). If the replaced fuse (No. 12) has blown out easily, repair short circuit of harness between fuse (No. 12) and TCM. Go to step 18.
Repair the open circuit of harness between fuse (No. 12) and TCM, or fuse (No. 12) and battery, and poor contact of the connector. Go to step 17.
4AT(diag)-28

Check Yes Is the fuse (No. 12) blown out? Replace the fuse (No. 12). If the replaced fuse (No. 12) has blown out easily, repair short circuit of harness between fuse (No. 12) and TCM. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 19. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 20 (B11) No. 20: (B55) No. 21 (B11) No. 20: (B55) No. 22 (B11) No. 19: (B55) No. 23 (B11) No. 19: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 20. TRANSMISSION AND TRANSMISSION GROUND. Measure the resistance of the harness between transmission and transmission ground. Connector & terminal (T4) No. 19 Transmission ground: (T4) No. 20 Transmission ground: CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM Repair the connecpower supply, ground and data tor. link connector? Step CHECK FUSE (NO. 12). Remove the fuse (F/B No. 12). No Repair the open circuit of harness between fuse (No. 12) and TCM, or fuse (No. 12) and battery, and poor contact of the connector. Repair the open circuit of harness between TCM and transmission harness connector, and poor contact of connector.
17
18
19
Repair the open circuit of the harness between transmission and transmission ground.
20
Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).>
4AT(diag)-29


A: LIST
DTC P0705 Item Transmission Range Sensor Circuit (PRNDL Input) Transmission Fluid Temperature Sensor Circuit Low Input Transmission Fluid Temperature Sensor Circuit High Input Input/Turbine Speed Sensor Circuit Brake Switch Circuit Low Output Speed Sensor Circuit Brake Switch Circuit High Engine Speed Input Circuit Gear 1 Incorrect Ratio Gear 2 Incorrect Ratio Gear 3 Incorrect Ratio Gear 4 Incorrect Ratio Reverse Incorrect Ratio Torque Converter Clutch Circuit Performance or Stuck Off Torque Converter Clutch Circuit Electrical Pressure Control Solenoid A Electrical Contents of diagnosis Inhibitor switch malfunction or short circuit Reference <Ref. to 4AT(diag)-32, DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-39, DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-42, DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-44, DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-46, DTC P0719 BRAKE SWITCH CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-49, DTC P0720 OUTPUT SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-51, DTC P0724 BRAKE SWITCH CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-53, DTC P0725 ENGINE SPEED INPUT CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-54, DTC P0731 GEAR 1 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-54, DTC P0732 GEAR 2 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-54, DTC P0733 GEAR 3 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-54, DTC P0734 GEAR 4 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-55, DTC P0736 REVERSE INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-56, DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-57, DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-60, DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0712
ATF temperature sensor is faulty or input signal circuit is open.
P0713
ATF temperature sensor is faulty or input signal circuit is shorted.
P0715
P0719
Torque converter turbine speed sensor malfunction, open or shorted input signal circuit Brake switch malfunction, open input signal circuit Front vehicle speed sensor malfunction, open or shorted input signal circuit Brake switch malfunction, shorted input signal circuit Open or shorted engine speed output signal circuit Vehicle sensor, torque converter turbine speed sensor or control valve malfunction Vehicle sensor, torque converter turbine speed sensor or control valve malfunction Vehicle sensor, torque converter turbine speed sensor or control valve malfunction Vehicle sensor, torque converter turbine speed sensor or control valve malfunction Vehicle sensor, torque converter turbine speed sensor or control valve malfunction Lock-up clutch is faulty or valve is stuck.
P0720
P0724
P0725
P0731
P0732
P0733
P0734
P0736
P0741
P0743
Lock-up solenoid is faulty or output signal circuit is open or shorted.
P0748
Line pressure linear solenoid is faulty or output signal circuit is open or shorted.
4AT(diag)-30

DTC P0753 Item Shift Solenoid A Electrical Shift Solenoid B Electrical Shift Solenoid C Electrical Shift Solenoid D Electrical Reverse Inhibit Control Circuit AT Vehicle Speed Sensor Circuit Malfunction (Rear Wheel) AT AWD Solenoid Valve Circuit Malfunction CAN Communication Circuit SPORT Mode Switch Circuit Contents of diagnosis Low clutch duty solenoid is faulty or output signal circuit is open or shorted. 2-4 brake duty solenoid is faulty or output signal circuit is open or shorted. High clutch duty solenoid is faulty or output signal circuit is open or shorted. Low & reverse clutch duty solenoid is faulty or output signal circuit is open or shorted. Shift lock solenoid is faulty or output signal circuit is open or shorted. Reference <Ref. to 4AT(diag)-62, DTC P0753 SHIFT SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-65, DTC P0758 SHIFT SOLENOID B ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0758
P0763
P0768
P0801
P1706
P1707
<Ref. to 4AT(diag)-68, DTC P0763 SHIFT SOLENOID C ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-71, DTC P0768 SHIFT SOLENOID D ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-74, DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear vehicle speed sensor is faulty or <Ref. to 4AT(diag)-76, DTC P1706 AT VEHICLE input signal circuit is open or shorted. SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Transfer duty solenoid is faulty or out- <Ref. to 4AT(diag)-78, DTC P1707 AT AWD SOLEput signal circuit is open or shorted. NOID VALVE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> CAN communication circuit is open or shorted. SPORT shift switch is faulty or input signal circuit is open or shorted. <Ref. to 4AT(diag)-80, DTC P1718 CAN COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 4AT(diag)-81, DTC P1817 SPORT MODE SWITCH CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1718
P1817
4AT(diag)-31


A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
DTC DETECTING CONDITION: Inhibitor switch is faulty. At least 2 range signal is input. TROUBLE SYMPTOM: Shift characteristics are erroneous. The range position of the select lever and the AT select lever position indicator light on the combination meter do not match.
4AT(diag)-32

WIRING DIAGRAM:
i106
No. 5
T7 1 2 3 4 5 6 7 8 9
i107 P R N D
COMBINATION METER
IGNITION SWITCH
MICRO COMPUTER CAN TRANSCEIVER & RECEIVER
1 2 3 4
i10
SBF-6
21
22
B12
WN WN
1 2 3 4 5 6 7 8 9 10 11 12
MAIN SBF
ON
ON
CAN JOINT CONNECTOR
* *
CAN JOINT CONNECTOR
B365
i106
ON ON BATTERY
i107
* *
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
WN WN
A27
A26
i10 B: B280 BODY INTEGRATED UNIT 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
A: B30
i84 B20
*1 *2
B365
*1 *2
B54 14 13 17 TCM 11 10 18
A:
i84
CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B12 3 2 1 8 T3 2 5 3 4
B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
P R N
INHIBITOR SWITCH T7 B54 1 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
* *1 *2
T3 4 B12
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 11, 12 AND 13 : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 8, 9, 10, 18, 19 AND 20
E
AT-04898
4AT(diag)-33

Step CHECK INDICATOR LIGHT. 1) Turn the ignition switch to ON. 2) Shift the select lever to P range. CHECK INDICATOR LIGHT. Check Does the P range indicator light on combination meter illuminate? Does the R range indicator light on combination meter illuminate? Does the N range indicator light on combination meter illuminate? Does the D range indicator light on combination meter illuminate? Is ON displayed? Yes Go to step 2. No Go to step 12.
Go to step 26.
Go to step 3.
CHECK INDICATOR LIGHT.
Go to step 33.
Go to step 4.
CHECK INDICATOR LIGHT.
Go to step 40.
Go to step 5.
10
CHECK P RANGE SWITCH. Read the data of P range using Subaru Select Monitor. CHECK INDICATOR LIGHT. Does the R range indicator Shift the select lever to R range. light on combination meter illuminate? CHECK R RANGE SWITCH. Is ON displayed? Read the data of R range using Subaru Select Monitor. CHECK INDICATOR LIGHT. Does the P range indicator Shift the select lever to N range. light on combination meter illuminate? CHECK N RANGE SWITCH. Is ON displayed? Read the data of N range using Subaru Select Monitor. CHECK INDICATOR LIGHT. Does the D range indicator Shift the select lever to D range. light on combination meter illuminate?
Go to step 19.
Go to step 6.
Go to step 8.
Go to step 7.
Go to step 23.
Go to step 20.
Go to step 10.
Go to step 9.
Go to step 30.
Go to step 27.
11
12
Is ON displayed? CHECK D RANGE SWITCH. Read the data of D range using Subaru Select Monitor. CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 : or more? Go to step 13. INHIBITOR SWITCH AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from inhibitor switch. 3) Measure the resistance of harness between inhibitor switch and chassis ground. Connector & terminal (T7) No. 5 Chassis ground:
Even if the ATF Go to step 11. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in TCM and transmission. Go to step 37. Go to step 34.
Repair the open circuit of harness between inhibitor switch and chassis ground, and poor contact of the connector.
4AT(diag)-34

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM and inhibitor switch. 3) Measure the resistance of the harness between TCM and inhibitor switch connector. Connector & terminal (B54) No. 14 (T7) No. 2: CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Connect the connector to TCM and inhibitor switch. 3) Turn the ignition switch to ON. 4) Shift the select lever to P range. 5) Measure the voltage between TCM and chassis ground. Connector & terminal (B54) No. 14 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. 1) Shift the select lever to any range other than P. 2) Measure the voltage between TCM and chassis ground. Connector & terminal (B54) No. 14 (+) Chassis ground (): CHECK BODY INTEGRATED UNIT. Read the data of Inhibitor Switch from Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Check DTC of body integrated unit. Check Yes Is the resistance less than 1 :? Go to step 14. No Repair the open circuit of harness between TCM and inhibitor switch connector, and poor contact of the connector.
13
14
Go to step 15.
Go to step 41.
15
Go to step 16.
16
Is 7 displayed?
Go to step 17.
17
18
19
20
Is DTC of CAN communication Perform the diag- Go to step 18. displayed? nosis according to DTC. CHECK COMBINATION METER. Is the P range indicator light Go to step 41. Replace the comCheck the P range indicator light. <Ref. to IDI- bulb OK? bination meter 5, INSPECTION, Combination Meter System.> assembly. <Ref. to IDI-22, Combination Meter.> CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 42. Repair ground TCM AND INHIBITOR SWITCH. more? short circuit in P 1) Turn the ignition switch to OFF. range circuit. 2) Disconnect the connectors from TCM, inhibitor switch and combination meter. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 14 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 21. Repair the open circuit of harness TCM AND INHIBITOR SWITCH. between TCM and 1) Turn the ignition switch to OFF. inhibitor switch 2) Disconnect the connector from TCM and connector, and inhibitor switch. poor contact of the 3) Measure the resistance of the harness connector. between TCM and inhibitor switch connector. Connector & terminal (B54) No. 13 (T7) No. 5:
4AT(diag)-35

Step CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Connect the connector to TCM and inhibitor switch. 3) Turn the ignition switch to ON. 4) Shift the select lever to R range. 5) Measure the voltage between TCM and chassis ground. Connector & terminal (B54) No. 13 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. 1) Shift the select lever to other than R range. 2) Measure the voltage between TCM and chassis ground. Connector & terminal (B54) No. 13 (+) Chassis ground (): CHECK BODY INTEGRATED UNIT. Read the data of Shift Position from Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Check DTC of body integrated unit. Check Is the voltage less than 1 V? Yes Go to step 22. No Go to step 41.
21
22
Go to step 41.
Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).> Check the body integrated unit.
23
Is 6 displayed?
Go to step 24.
24
25
26
27
28
Is DTC of CAN communication Perform the diag- Go to step 25. displayed? nosis according to DTC. CHECK COMBINATION METER. Is the R range indicator light Go to step 41. Replace the comCheck the R range indicator light. <Ref. to IDI- OK? bination meter assembly. <Ref. to 5, INSPECTION, Combination Meter System.> IDI-22, Combination Meter.> CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 41. Repair ground TCM AND INHIBITOR SWITCH. more? short circuit in R 1) Turn the ignition switch to OFF. range circuit. 2) Disconnect the connectors from TCM, inhibitor switch and combination meter. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 13 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 28. Repair the open TCM AND INHIBITOR SWITCH. circuit of harness 1) Turn the ignition switch to OFF. between TCM and 2) Disconnect the connector from TCM and inhibitor switch inhibitor switch. connector, and 3) Measure the resistance of the harness poor contact of the between TCM and inhibitor switch connector. connector. Connector & terminal (B54) No. 11 (T7) No. 3: CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 29. Go to step 41. 1) Turn the ignition switch to OFF. 2) Connect the connector to TCM and inhibitor switch. 3) Turn the ignition switch to ON. 4) Shift the select lever to N range. 5) Measure the voltage between TCM and chassis ground. Connector & terminal (B54) No. 11 (+) Chassis ground ():
4AT(diag)-36

Step CHECK INPUT SIGNAL FOR TCM. 1) Shift the select lever to any range other than N range. 2) Measure the voltage between TCM and chassis ground. Connector & terminal (B54) No. 11 (+) Chassis ground (): CHECK BODY INTEGRATED UNIT. Read the data of Shift Position from Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Check DTC of body integrated unit. Check Is the voltage 8 V or more? Yes Go to step 41. No Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).>
29
30
Is 5 displayed?
Go to step 31.
31
32
33
34
35
36
37
Is DTC of CAN communication Perform the diag- Go to step 32. displayed? nosis according to DTC. CHECK COMBINATION METER. Is the N range indicator light Go to step 41. Replace the comCheck the N range indicator light. <Ref. to IDI- OK? bination meter assembly. <Ref. to 5, INSPECTION, Combination Meter System.> IDI-22, Combination Meter.> CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 41. Repair the ground TCM AND INHIBITOR SWITCH. more? short circuit in N 1) Turn the ignition switch to OFF. range circuit. 2) Disconnect the connectors from TCM, inhibitor switch and combination meter. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 11 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 35. Repair the open TCM AND INHIBITOR SWITCH. circuit of harness 1) Turn the ignition switch to OFF. between TCM and 2) Disconnect the connector from TCM and inhibitor switch inhibitor switch. connector, and 3) Measure the resistance of the harness poor contact of the between TCM and inhibitor switch connector. connector. Connector & terminal (B54) No. 10 (T7) No. 4: CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 36. Go to step 41. 1) Turn the ignition switch to OFF. 2) Connect the connector to TCM and inhibitor switch. 3) Turn the ignition switch to ON. 4) Shift the select lever to D range. 5) Measure the voltage between TCM and chassis ground. Connector & terminal (B54) No. 10 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Is the voltage 8 V or more? Go to step 41. Replace the TCM. 1) Shift the select lever to any range other than <Ref. to 4AT-61, D range. Transmission Con2) Measure the voltage between TCM and trol Module chassis ground. (TCM).> Connector & terminal (B54) No. 10 (+) Chassis ground (): Is 4 displayed? Go to step 38. Check the body CHECK BODY INTEGRATED UNIT. integrated unit. Read the data of Inhibitor Switch from Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.>
4AT(diag)-37

Step CHECK BODY INTEGRATED UNIT. Check DTC of body integrated unit. Check Yes No Is DTC of CAN communication Perform the diag- Go to step 39. displayed? nosis according to DTC. CHECK COMBINATION METER. Is the D range indicator light Go to step 41. Replace the comCheck the D range indicator light. <Ref. to IDI- OK? bination meter 5, INSPECTION, Combination Meter System.> assembly. <Ref. to IDI-22, Combination Meter.> CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 41. Repair ground TCM AND INHIBITOR SWITCH. more? short circuit in D 1) Turn the ignition switch to OFF. range circuit. 2) Disconnect the connectors from TCM, inhibitor switch and combination meter. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 10 Chassis ground: CHECK POOR CONTACT. Is there poor contact in the Repair the poor Go to step 42. inhibitor switch circuit? contact. CHECK INHIBITOR SWITCH. Is the inhibitor switch in the nor- Replace the TCM. Adjust inhibitor switch and select mal position? <Ref. to 4AT-61, Transmission Con- cable. <Ref. to 4AT-46, Inhibitor trol Module (TCM).> Switch.> <Ref. to CS-28, Select Cable.>
38
39
40
41 42
4AT(diag)-38

B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Input signal circuit to ATF temperature sensor is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
AT2
B54
TCM
1 2 3 4 5 6 7 8 9 10
23
12
B11 B11 11 15 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT2 B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
ATF TEMPERATURE SENSOR
CONTROL VALVE BODY
AT-04767
4AT(diag)-39

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission and TCM. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 23 (B11) No. 11: CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 12 (B11) No. 15: CHECK ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Connect the connectors to transmission and TCM. 3) Turn the ignition switch to ON and start engine. 4) Warm up the transmission until the ATF temperature exceeds 80C (176F). NOTE: If the ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Disconnect the connector from transmission. 6) Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 11 No. 15: CHECK ATF TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 11 No. 15: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect the connector to transmission. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON (engine OFF). 4) Read the data of ATF temperature sensor using Subaru Select Monitor. Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and transmission connector.
Repair the open circuit of harness between TCM and transmission connector. Go to step 7.
Does the resistance value Go to step 5. increase while the ATF temperature decreases?
Go to step 7.
Does the ATF temperature gradually decrease?
CHECK POOR CONTACT.
Is there poor contact in ATF temperature sensor circuit?
Even if the ATF Go to step 6. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness and poor contact of ATF temperature sensor and transmission connector. Repair the poor Replace the TCM. contact. <Ref. to 4AT-61, Transmission Control Module (TCM).>
4AT(diag)-40

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve connector. 7) Measure the resistance of harness between ATF temperature sensor and transmission connector. Connector & terminal (T4) No. 11 (AT2) No. 4: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. Measure the resistance of harness between ATF temperature sensor and transmission connector. Connector & terminal (T4) No. 15 (AT2) No. 9: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 11 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 15 Transmission ground: Check Yes Is the resistance less than 1 :? Go to step 8. No Repair the open circuit of harness between ATF temperature sensor and transmission connector.
Repair the open circuit of harness between ATF temperature sensor and transmission connector.
Go to step 10.
Repair the short circuit of harness between ATF temperature sensor and transmission connector.
10
Replace the control valve body. <Ref. to 4AT-56, Control Valve Body.>
Repair the short circuit of harness between ATF temperature sensor and transmission connector.
4AT(diag)-41

C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Input signal circuit to ATF temperature sensor is shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
AT2
B54
TCM
1 2 3 4 5 6 7 8 9 10
23
12
B11 B11 11 15 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT2 B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
CONTROL VALVE BODY
AT-04767
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM. 3) Measure the resistance between TCM connector terminals. Connector & terminal (B54) No. 23 No. 12: CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 23 Chassis ground: CHECK HARNESS. Measure the resistance between TCM connector terminals while shaking the harness. Connector & terminal (B54) No. 23 No. 12: CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 23 Chassis ground:
Check Is the resistance 500 : or more?
Yes Go to step 2.
No Go to step 4.
Go to step 3.
Go to step 4.
Does the resistance change?
Go to step 4.
Go to step 5.
Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).> Repair the short circuit of harness between TCM and transmission harness.
4AT(diag)-42

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 12 Chassis ground: CHECK ATF TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 11 No. 15: Check Is the resistance 1 M: or more? Yes Go to step 6. No Repair the short circuit of harness between TCM and transmission harness.
Is the resistance 500 : or more?
CHECK TRANSMISSION HARNESS. 1) Lift up the vehicle. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the oil pan. 4) Disconnect the harness connector from control valve. 5) Measure the resistance between ATF temperature sensor connector terminals. 6) Measure the resistance between transmission connector and transmission ground. Connector & terminal (T4) No. 11 Transmission ground: CHECK TRANSMISSION HARNESS. Measure the resistance between transmission connector and transmission ground. Connector & terminal (T4) No. 15 Transmission ground: CHECK ATF TEMPERATURE SENSOR. Measure the resistance between control valve connector terminals. Terminals No. 4 No. 9:
Even if the ATF Go to step 7. temperature warning light blinks, the circuit is in normal condition at this time. A temporary short circuit of connector or harness may be the cause. Repair the harness or connector. Go to step 8. Replace the transmission harness.
Go to step 9.
Replace the transmission harness.
Is the resistance 500 : or more?
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary short circuit of connector or harness may be the cause. Repair the harness or connector.
4AT(diag)-43

D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT

DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
B54
TCM 1 2
B11
3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 JOINT CONNECTOR
B53
* *
B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 B11 5 10 T4
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 2, 3 AND 13
5 6 14 15 16 25 26 27 33 34 35
B53
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
TORQUE CONVERTER TURBINE SPEED SENSOR
AT-04330
4AT(diag)-44

Step Check Yes CHECK TORQUE CONVERTER TURBINE Is the resistance 450 650 :? Go to step 2. SPEED SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Measure the resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 5 No. 10: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 3. TCM AND TRANSMISSION. 1) Disconnect the connector from TCM. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 1 (B11) No. 5: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 4. TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 2 (B11) No. 10: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 2 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 1 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect the connectors to TCM and transmission. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON and run the Subaru Select Monitor. 4) Start the engine. 5) Shift the select lever to P or N range. 6) Read the data of Turbine Revolution Speed using Subaru Select Monitor. Compare the tachometer with Subaru Select Monitor indications. CHECK POOR CONTACT. Is the resistance 1 M: or more? Go to step 5. No Replace the torque converter turbine speed sensor. <Ref. to 4AT-53, Torque Converter Turbine Speed Sensor.>
Repair the open circuit of harness between TCM and transmission connector.
Repair the open circuit of harness between TCM and transmission connector, and poor contact of the connector. Repair the short circuit of harness between TCM and transmission connector. Repair the short circuit of the harness between TCM and transmission connector, and poor contact of connector. Go to step 7.
Go to step 6.
Is the revolution value same as Even if the ATF the tachometer reading shown temperature warnon the combination meter? ing light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in TCM and transmission. Is there poor contact in torque Repair the poor converter turbine speed sensor contact. circuit?
4AT(diag)-45

E: DTC P0719 BRAKE SWITCH CIRCUIT LOW

DTC DETECTING CONDITION: Brake switch malfunction, open input signal circuit TROUBLE SYMPTOM: Gear is not shifted down when driving a down hill. WIRING DIAGRAM:
MAIN SBF
SBF-2
B65
1 3
BATTERY
2 4
No.8
B159
1 2 3 4 5 6 7 8 9
2
STOP LIGHT SWITCH
B: B280
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
E
3
B65
FUSE & RELAY BOX (F/B)
C: B281
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 27 28 22 23 24 25 26
9 3 5
B159
B54
B225
7.5A
FUSE (RELAY BLOCK)
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
5 6 14 15 16 25 26 27 33 34 35
C23
B365
B: B280
BODY INTEGRATED UNIT
B20 B30
*2
*2
C: B281
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B225 (BLACK)
CAN JOINT CONNECTOR

B365
1 3 5 7
2 4 6 8
9 10 11 12 25 26 27 28
13 14 15 16 29 30 31 32
17 18 19 20 33 34 35 36
21 22 23 24 37 38 39 40
18
B54
TCM
17
*2
AT-04331
4AT(diag)-46

Step 1 CHECK DTC. Check Yes Is DTC of CAN communication Perform the diagdisplayed? nosis according to DTC. Is the fuse (No. 8) blown out? Replace the fuse (No. 8). If the replaced fuse (No. 8) has blown out easily, repair the short circuit of harness between fuse (No. 8) and stop light switch. Is the fuse (7.5A) blown out? Replace the fuse (7.5A). If the replaced fuse (7.5A) blows out easily, repair the short circuit of harness between fuse (7.5A) and TCM. Is ON displayed? Go to step 5. No Go to step 2.
CHECK FUSE (NO. 8). 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 8).
Go to step 3.
CHECK FUSE (RELAY BLOCK) (7.5A). Remove the fuse (relay block) (7.5 A).
Go to step 4.
CHECK BODY INTEGRATED UNIT. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. (engine OFF) 4) Run the Subaru Select Monitor. 5) Depress the brake pedal. 6) Read the data of Stop Light Switch using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> Is ON displayed? CHECK TCM. Read the data of Stop Light Switch using Subaru Select Monitor. <Ref. to 4AT(diag)-16, OPERATION, Subaru Select Monitor.>
Go to step 6.
CHECK BODY INTEGRATED UNIT INPUT Is the voltage 10 V or more? SIGNAL. 1) Disconnect the connector from body integrated unit. 2) Depress the brake pedal. 3) Measure the voltage of harness between the body integrated unit and chassis ground. Connector & terminal (B281) No. 23 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 8. BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from stop light switch. 3) Measure the resistance of harness between body integrated unit and stop light switch. Connector & terminal (B281) No. 23 (B65) No. 3:
A temporary poor contact of connector or harness may be the cause. Check the poor contact. Go to step 9.
Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).> Go to step 7.
Repair the open circuit of harness between body integrated unit and stop light switch.
4AT(diag)-47

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or BODY INTEGRATED UNIT AND STOP LIGHT more? SWITCH. Measure the resistance of harness between body integrated unit and stop light switch. Connector & terminal (B281) No. 23 Chassis ground: CHECK POOR CONTACT. Is there poor contact in input signal of brake switch? Yes Go to step 9. No Repair the short circuit of harness between body integrated unit and stop light switch.
Repair the poor contact.
4AT(diag)-48

F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT

DTC DETECTING CONDITION: The vehicle speed signal is abnormal. The harness connector between TCM and front vehicle speed sensor is shorted or open. TROUBLE SYMPTOM: Driving performance is poor. WIRING DIAGRAM:
B54
TCM B11
27
16
*
*
JOINT CONNECTOR
3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5
1 2
*
B53
B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B11 14 18 T4
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 11 AND 12
B53
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
FRONT VEHICLE SPEED SENSOR
AT-04332
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 27 (B11) No. 14: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 3. TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 16 (B11) No. 18: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or TCM AND TRANSMISSION. more? Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 27 Chassis ground: Go to step 4.
No Repair the open circuit of harness between TCM and transmission connector.
Repair the open circuit of harness between TCM and transmission connector, and poor contact of the connector. Repair the short circuit of harness between TCM and transmission connector.
4AT(diag)-49

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or TCM AND TRANSMISSION. more? Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 16 Chassis ground: CHECK FRONT VEHICLE SPEED SENSOR. Measure the resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 14 No. 18: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Connect the Subaru Select Monitor to data link connector. 3) Lift up the vehicle. 4) Turn the ignition switch to ON and run the Subaru Select Monitor. 5) Start the engine. 6) Read the data of Front Wheel Speed using Subaru Select Monitor. Compare the speedometer with Subaru Select Monitor indications. Vehicle speed is indicated in km/h or MPH 7) Slowly increase the vehicle speed to 60 km/ h (37 MPH). NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> CHECK POOR CONTACT. Yes Go to step 5. No Repair the short circuit of the harness between TCM and transmission connector, and poor contact of connector. Replace the front vehicle speed sensor. <Ref. to 4AT49, Front Vehicle Speed Sensor.> Go to step 7.
Is the resistance 450 650 :? Go to step 6.
Does the speedometer indication increase as the Subaru Select Monitor front wheel speed data increases?
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness in of front vehicle speed sensor circuit.
Is there poor contact in front vehicle speed sensor circuit?
4AT(diag)-50

G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH

DTC DETECTING CONDITION: Brake switch malfunction, open input signal circuit TROUBLE SYMPTOM: Gear is not shifted down when driving a down hill. WIRING DIAGRAM:
MAIN SBF
SBF-2
B65
1 3
BATTERY
2 4
No.8
B159
1 2 3 4 5 6 7 8 9
2
STOP LIGHT SWITCH
B: B280
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
E
3
B65
C: B281
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 27 28 22 23 24 25 26
9 3 5
B159
B54
B225
7.5A
FUSE (RELAY BLOCK)
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
5 6 14 15 16 25 26 27 33 34 35
C23
B365
B: B280
B20 B30
*2
*2
C: B281
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B225 (BLACK)
CAN JOINT CONNECTOR

B365
1 3 5 7
2 4 6 8
9 10 11 12 25 26 27 28
13 14 15 16 29 30 31 32
17 18 19 20 33 34 35 36
21 22 23 24 37 38 39 40
18
B54
TCM
17
*2
AT-04331
4AT(diag)-51

Step 1 CHECK DTC. Check Yes No Is DTC of CAN communication Perform the diag- Go to step 2. displayed? nosis according to DTC. Is OFF displayed? Go to step 3. Go to step 4.
CHECK BODY INTEGRATED UNIT. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. (engine OFF) 4) Run the Subaru Select Monitor. 5) Read the data of Stop Light Switch using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK TCM. Is OFF displayed? Read the data of Stop Light Switch using Subaru Select Monitor. <Ref. to 4AT(diag)-16, OPERATION, Subaru Select Monitor.>
CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Disconnect the harness connector of body integrated unit. 2) Measure the voltage of harness between body integrated unit and stop light switch. Connector & terminal (B281) No. 23 (+) Chassis ground (): CHECK STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from stop light switch. 3) Measure the resistance of harness between stop light switch connectors. Terminals No. 2 No. 3: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. 1) Turn the ignition switch to ON. 2) Measure the voltage of harness between the body integrated unit and chassis ground. Connector & terminal (B281) No. 23 (+) Chassis ground (): CHECK POOR CONTACT.
Go to step 6.
Replace the stop light switch.
Go to step 7.
Repair the short circuit of harness between TCM and stop light switch.
Is there poor contact in input signal of brake switch?
4AT(diag)-52

H: DTC P0725 ENGINE SPEED INPUT CIRCUIT

DTC DETECTING CONDITION: Engine speed input signal circuit is open or shorted. TROUBLE SYMPTOM: No lock-up occurs. (After engine is warmed up) ATF temperature warning light remains ON when the vehicle speed is 0. WIRING DIAGRAM:
B55
TCM B55 11
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35
B136
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B136
22 ECM
AT-04333
4AT(diag)-53

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and ECM. 3) Measure the resistance of harness between TCM and ECM. Connector & terminal (B55) No. 11 (B136) No. 22: CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 11 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect the connectors to TCM and ECM. 2) Connect the Subaru Select Monitor to data link connector. 3) Start the engine, and run the Subaru Select Monitor. 4) Idle the engine. 5) Read the data of Engine Speed using Subaru Select Monitor. Display shows engine speed signal value sent from ECM. CHECK POOR CONTACT. CONFIRM DTC P0725. Replace the ECM with a new part. Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and ECM connector.
Go to step 3.
Repair the short circuit of harness between TCM and ECM connector.
4 5
Is the revolution value same as Even if the ATF Go to step 4. the tachometer reading shown temperature warnon the combination meter? ing light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in the TCM and ECM. Is there poor contact in engine Repair the poor Go to step 5. speed signal circuit? contact. Does the DTC appear again, Replace the TCM. Replace the ECM. after the memory has been <Ref. to 4AT-61, cleared? Transmission Control Module (TCM).>
I:
DTC P0731 GEAR 1 INCORRECT RATIO
NOTE: Refer to DTC P0736 for diagnostic procedure. <Ref. to 4AT(diag)-55, DTC P0736 REVERSE INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC P0732 GEAR 2 INCORRECT RATIO

K: DTC P0733 GEAR 3 INCORRECT RATIO

L: DTC P0734 GEAR 4 INCORRECT RATIO

4AT(diag)-54

M: DTC P0736 REVERSE INCORRECT RATIO

DTC DETECTING CONDITION: Vehicle sensor, torque converter turbine speed sensor or control valve malfunction TROUBLE SYMPTOM: Shift point is too high or too low. Excessive shift shock Tight corner braking phenomenon occurs. Gear is not shifted to reverse. Gear position is held by fail safe function.
1 Step CHECK ACCELERATOR PEDAL POSITION SENSOR. 1) Connect the Subaru Select Monitor to data link connector. 2) Turn the ignition switch to ON. 3) Read the value of Accel. opening angle on Subaru Select Monitor display. CHECK FRONT VEHICLE SPEED SENSOR. 1) Lift up the vehicle. 2) Start the engine. 3) Shift the select lever to D range and slowly increase vehicle speed. NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> CHECK TORQUE CONVERTER TURBINE SPEED SENSOR. 1) Shift the select lever to P or N range. 2) Idle the engine. Check Yes Does the value of Accel. open- Go to step 2. ing angle change from 0% to 100% smoothly when throttle is operated from fully closed to fully open? No Check the accelerator pedal position sensor circuit.
Does the vehicle speed disGo to step 3. played by Subaru Select Monitor roughly correspond with vehicle speed indicated by the combination meter?
Check the front vehicle speed sensor circuit.
Does the value of torque converter turbine speed sensor displayed by Subaru Select Monitor roughly correspond with the value of tachometer in combination meter?
There are malfunctions in TCM, TCM connector poor contact, or transmission assembly mechanical malfunction.
Check the torque converter turbine speed sensor circuit.
4AT(diag)-55

N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF

DTC DETECTING CONDITION: Lock up clutch malfunction Sticky valve TROUBLE SYMPTOM: No lock-up occurs.
1 Step Check CHECK LOCK-UP DUTY SOLENOID CIRIs there any fault? CUIT. Diagnose according to DTC P0743 procedure. CHECK INHIBITOR SWITCH CIRCUIT. Is there any fault? Diagnose according to DTC P0705 procedure. CHECK STOP LIGHT SWITCH CIRCUIT. Diagnose according to DTC P0719 and P0724 procedures. CHECK ATF TEMPERATURE SENSOR CIRCUIT. Diagnose according to DTC P0712 and P0713 procedure. CHECK ACCELERATOR PEDAL POSITION SENSOR. 1) Connect the Subaru Select Monitor to data link connector. 2) Turn the ignition switch to ON. 3) Read the value of Accel. opening angle on Subaru Select Monitor display. CHECK TORQUE CONVERTER TURBINE SPEED SENSOR. 1) Shift the select lever to P or N range. 2) Idle the engine. CHECK ENGINE SPEED SIGNAL. Idle the engine. Is there any fault? Yes Repair or replace the lock up duty solenoid circuit. Repair or replace the inhibitor switch circuit. Repair or replace the stop light switch circuit. Repair or replace the ATF temperature sensor circuit. Go to step 6. No Go to step 2.
Go to step 3.
Go to step 4.
Is there any fault?
Go to step 5.
Does the value of accelerator pedal position sensor change from 0% to 100% smoothly when throttle is operated from fully closed to fully open?
Check the accelerator pedal position sensor circuit.
Does the value of turbine speed displayed by Subaru Select Monitor almost correspond with the value of the tachometer? Does the value of turbine speed displayed by Subaru Select Monitor almost correspond with the value of the tachometer?
Check the torque converter turbine speed sensor circuit. There is transmis- Check the engine sion assembly speed signal cirmechanical malcuit. function.
Go to step 7.
4AT(diag)-56

O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of lock-up duty solenoid is open or shorted. TROUBLE SYMPTOM: No lock-up occurs. (After engine is warmed up) WIRING DIAGRAM:
AT2
B54
TCM
1 2 3 4 5 6 7 8 9 10
B11 12 B11 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT 2
LOCK-UP DUTY SOLENOID
B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
CONTROL VALVE BODY
AT-04768
4AT(diag)-57

Step CHECK DTC. CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 6 (B11) No. 12: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of the harness connector between TCM connector and chassis ground. Connector & terminal (B54) No. 6 Chassis ground: CHECK LOCK-UP DUTY SOLENOID. Measure the resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 12 No. 20: CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Connect the connectors to TCM and transmission. 2) Lift up the vehicle. 3) Connect the Subaru Select Monitor to data link connector. 4) Start the engine, and run the Subaru Select Monitor. 5) Start the engine and warm up the engine until the ATF temperature exceeds 80C (176F). NOTE: If the ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 6) Read the data of Lock Up Duty Ratio using Subaru Select Monitor. Lock-up duty solenoid is indicated in %. 7) Shift the select lever to D, and slowly increase vehicle speed to 60 km/h (37 MPH). NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> Check Yes Are multiple DTCs displayed? Go to other DTC. Is the resistance less than 1 :? Go to step 3. No Go to step 2. Repair the open circuit of harness between TCM and transmission connector.
1 2
Go to step 4.
Repair the short circuit of harness between TCM and transmission connector.
Is the resistance 2.0 6.0 :? Go to step 5.
Go to step 8.
Is the measured value 95%?
Go to step 6.
Go to step 7.
4AT(diag)-58

Step Check CHECK OUTPUT SIGNAL FROM TCM USIs the measured value 5%? ING SUBARU SELECT MONITOR. Return the engine to idling speed, shift the select lever to N range and read the data. NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> CHECK POOR CONTACT. Is there poor contact in lock-up duty solenoid circuit? Yes No Even if the ATF Go to step 7. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in TCM and transmission. Repair the poor contact. Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).> Replace the control valve body. <Ref. to 4AT-56, Control Valve Body.>
10
CHECK LOCK-UP DUTY SOLENOID (IN TRANSMISSION). 1) Disconnect the transmission connector. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the oil pan, and disconnect the connector from control valve body. 4) Measure the resistance between lock-up duty solenoid and transmission ground. Connector & terminal (AT2) No. 6 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN LOCK-UP DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between lock-up duty solenoid and transmission connector. Connector & terminal (T4) No. 12 (AT2) No. 6: CHECK HARNESS CONNECTOR BETWEEN LOCK-UP DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 12 Transmission ground:
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in lock-up duty solenoid and transmission.
Repair the short circuit of harness between lock-up duty solenoid and transmission connector.
4AT(diag)-59

P: DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of line pressure linear solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
AT2 B54
TCM
4 3
1 2 3 4 5 6 7 8 9 10
B11 B11 1 2 T4
3 4 6 7 8 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
5 10
AT2 B54
LINE PRESSURE LINEAR SOLENOID
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
5 6 14 15 16 25 26 27 33 34 35
CONTROL VALVE BODY
AT-04769
4AT(diag)-60

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission and TCM. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 3 (B11) No. 2: (B54) No. 4 (B11) No. 1: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 3 Chassis ground: (B54) No. 4 Chassis ground: CHECK LINE PRESSURE LINEAR SOLENOID. Measure the resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 1 No. 2: CHECK LINE PRESSURE LINEAR SOLENOID (IN TRANSMISSION). 1) Remove the transmission connector from bracket. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the oil pan, and disconnect the connector from control valve body. 4) Measure the resistance of line pressure linear solenoid connector terminals. Connector & terminal (AT2) No. 5 No. 10: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LINE PRESSURE LINEAR SOLENOID. Measure the resistance of harness between line pressure linear solenoid and transmission connector. Connector & terminal (T4) No. 2 (AT2) No. 10: (T4) No. 1 (AT2) No. 5: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LINE PRESSURE LINEAR SOLENOID. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 1 Transmission ground: (T4) No. 2 Transmission ground: Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and transmission connector.
Go to step 3.
Is the resistance 4 8 :?
Go to step 5.
Go to step 4.
Go to step 5.
Repair the open circuit of harness between line pressure linear solenoid and transmission connector.
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in line pressure linear solenoid and transmission.
Repair the short circuit of harness between line pressure linear solenoid and transmission connector.
4AT(diag)-61

Q: DTC P0753 SHIFT SOLENOID A ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of low clutch duty solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
AT2 B55 TCM 1 2 3 4 5 6 7 8 9 10
B11 B11 4 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT 2 B55 LOW CLUTCH DUTY SOLENOID 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31 4 5 6 7 14 15 16 17 18 19 24 25 26 27 32 33 34 35
CONTROL VALVE BODY
AT-04770
4AT(diag)-62

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 7 (B11) No. 4: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and transmission ground. Connector & terminal (B55) No. 7 Chassis ground: CHECK LOW CLUTCH DUTY SOLENOID. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 4 No. 20: CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Connect the connectors to TCM and transmission. 2) Connect the Subaru Select Monitor to data link connector. 3) Start the engine, and run the Subaru Select Monitor. 4) Warm up the transmission until the ATF temperature exceeds approximately 80C (176F). NOTE: If the ambient temperature falls below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Stop the engine and turn the ignition switch to ON (with engine OFF). 6) Shift the select lever to P or N range, and depress the accelerator pedal. 7) Read the data of Low Clutch Duty using Subaru Select Monitor. Low clutch duty solenoid is indicated in %. CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Turn the ignition switch to ON (engine OFF). 2) Shift the select lever to D range. 3) Read the data of Low Clutch Duty. Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and transmission connector.
Go to step 3.
Repair the short circuit of harness between TCM and transmission connector. Go to step 7.
Go to step 5.
Go to step 6.
CHECK POOR CONTACT.
Is there poor contact in low clutch duty solenoid circuit?
Even if the ATF Go to step 6. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in transmission. Repair the poor Replace the TCM. contact. <Ref. to 4AT-61, Transmission Control Module (TCM).>
4AT(diag)-63

Step CHECK LOW CLUTCH DUTY SOLENOID (IN TRANSMISSION). 1) Remove the transmission connector from bracket. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the oil pan, and disconnect the connector from control valve body. 4) Measure the resistance between low clutch duty solenoid connector and transmission ground. Connector & terminal (AT2) No. 2 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LOW CLUTCH DUTY SOLENOID. Measure the resistance of harness between low clutch duty solenoid and transmission connector. Connector & terminal (T4) No. 4 (AT2) No. 2: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LOW CLUTCH DUTY SOLENOID. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 4 Transmission ground: Check Yes Is the resistance 2.0 6.0 :? Go to step 8. No Replace the control valve body. <Ref. to 4AT-56, Control Valve Body.>
Repair the open circuit of harness between low clutch duty solenoid and transmission connector.
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector of the low clutch duty solenoid and transmission.
Repair the short circuit of harness between low clutch duty solenoid and transmission connector.
4AT(diag)-64

R: DTC P0758 SHIFT SOLENOID B ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of 2-4 brake duty solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
AT2 B55 TCM 1 2 3 4 5 6 7 8 9 10
B11 B11 3 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT 2 B55 2-4 BRAKE DUTY SOLENOID 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31 4 5 6 7 14 15 16 17 18 19 24 25 26 27 32 33 34 35
CONTROL VALVE BODY
AT-04771
4AT(diag)-65

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 4 (B11) No. 3: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 4 Chassis ground: CHECK 2-4 BRAKE DUTY SOLENOID. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 3 No. 20: CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Connect the Subaru Select Monitor to data link connector. 3) Start the engine, and run the Subaru Select Monitor. 4) Warm up the transmission until the ATF temperature exceeds approximately 80C (176F). NOTE: If the ambient temperature falls below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Stop the engine and turn the ignition switch to ON (with engine OFF). 6) Shift the select lever to N range, and depress the accelerator pedal. 7) Read the data of Brake Clutch Duty Ratio using Subaru Select Monitor. 2-4 brake duty solenoid is indicated in %. CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. Shift the select lever to 2nd on manual mode. Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and transmission connector.
Go to step 3.
Go to step 5.
Go to step 6.
CHECK POOR CONTACT.
Is there poor contact in 2-4 brake duty solenoid circuit?
Even if the ATF Go to step 6. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in TCM and transmission. Repair the poor Replace the TCM. contact. <Ref. to 4AT-61, Transmission Control Module (TCM).>
4AT(diag)-66

Step CHECK 2-4 BRAKE DUTY SOLENOID (IN TRANSMISSION). 1) Remove the transmission connector from bracket. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the oil pan, and disconnect the connector from 2-4 brake duty solenoid. 4) Measure the resistance of harness between 2-4 brake duty solenoid connector and transmission ground. Connector & terminal (AT2) No. 8 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN 2-4 BRAKE DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between 2-4 brake duty solenoid and transmission connector. Connector & terminal (T4) No. 3 (AT2) No. 8: CHECK HARNESS CONNECTOR BETWEEN 2-4 BRAKE DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 3 Transmission ground: Check Yes Is the resistance 2.0 6.0 :? Go to step 8. No Replace the control valve body. <Ref. to 4AT-56, Control Valve Body.>
Repair the open circuit of harness between 2-4 brake duty solenoid and transmission connector.
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in 2-4 brake duty solenoid and transmission.
Repair the short circuit of harness between 2-4 brake duty solenoid and transmission connector.
4AT(diag)-67

S: DTC P0763 SHIFT SOLENOID C ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of high clutch duty solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
AT2 B55 TCM 1 2 3 4 5 6 7 8 9 10
B11 B11 7 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT 2 B55 HIGH CLUTCH DUTY SOLENOID 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31 4 5 6 7 14 15 16 17 18 19 24 25 26 27 32 33 34 35
CONTROL VALVE BODY
AT-04772
4AT(diag)-68

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 6 (B11) No. 7: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of the harness connector between TCM connector and chassis ground. Connector & terminal (B55) No. 6 Chassis ground: CHECK HIGH CLUTCH DUTY SOLENOID. Measure the resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 7 No. 20: CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Connect the connectors to TCM and transmission. 2) Lift up the vehicle. 3) Connect the Subaru Select Monitor to data link connector. 4) Start the engine, and run the Subaru Select Monitor. 5) Start the engine and warm up the engine until the ATF temperature exceeds 80C (176F). NOTE: If the ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 6) Read the data of High Clutch Duty using Subaru Select Monitor. High clutch duty solenoid is indicated in %. 7) Shift the select lever to D, and slowly increase vehicle speed to measure at 3rd or 4th. NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and transmission connector.
Go to step 3.
Go to step 7.
Go to step 5.
Go to step 6.
4AT(diag)-69

Step Check CHECK OUTPUT SIGNAL FROM TCM USIs the measured value 100%? ING SUBARU SELECT MONITOR. Return the engine to idling speed and shift the select lever to N range. NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> CHECK POOR CONTACT. Is there poor contact in high clutch duty solenoid circuit? Yes No Even if the ATF Go to step 6. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in TCM and transmission. Repair the poor contact. Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).> Replace the control valve body. <Ref. to 4AT-56, Control Valve Body.>
CHECK HIGH CLUTCH DUTY SOLENOID (IN TRANSMISSION). 1) Remove the transmission connector from bracket. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the oil pan, and disconnect the control valve body connector. 4) Measure the resistance between high clutch duty solenoid connector and transmission ground. Connector & terminal (AT2) No. 3 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN HIGH CLUTCH DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between high clutch duty solenoid and transmission connector. Connector & terminal (T4) No. 7 (AT2) No. 3: CHECK HARNESS CONNECTOR BETWEEN HIGH CLUTCH DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 7 Transmission ground:
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in high clutch duty solenoid and transmission.
Repair the short circuit of harness between high clutch duty solenoid and transmission connector.
4AT(diag)-70

T: DTC P0768 SHIFT SOLENOID D ELECTRICAL

DTC DETECTING CONDITION: The output signal circuit of low & reverse duty solenoid is open or shorted. TROUBLE SYMPTOM: Gear is not changed. WIRING DIAGRAM:
AT2 B55 TCM 1 2 3 4 5 6 7 8 9 10
B11 B11 6 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT 2 B55 LOW & REVERSE DUTY SOLENOID 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31 4 5 6 7 14 15 16 17 18 19 24 25 26 27 32 33 34 35
CONTROL VALVE BODY
AT-04773
4AT(diag)-71

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission and TCM. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 5 (B11) No. 6: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 5 Chassis ground: CHECK LOW & REVERSE DUTY SOLENOID. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 6 No. 20: CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Connect the Subaru Select Monitor to data link connector. 3) Start the engine, and run the Subaru Select Monitor. 4) Warm up the transmission until the ATF temperature exceeds approximately 80C (176F). NOTE: If the ambient temperature falls below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Stop the engine and turn the ignition switch to ON (with engine OFF). 6) Shift the select lever to N range. 7) Read the data of L&R/B Duty using Subaru Select Monitor. Low & reverse duty solenoid is indicated in %. CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Lift up the vehicle. 2) Shift the select lever to manual mode, and then hold it on 1st. Slowly increase the vehicle speed up to 15 km/h (9 MPH), and then return the accelerator pedal. NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Read the data of L&R/B Duty. Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and transmission connector.
Go to step 3.
Go to step 5.
Go to step 6.
Even if the ATF Go to step 6. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in TCM and transmission.
4AT(diag)-72

Step CHECK POOR CONTACT. Check Yes Is there poor contact in the low Repair the poor & reverse duty solenoid circuit? contact. No Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).> Replace the control valve body. <Ref. to 4AT-56, Control Valve Body.>
CHECK LOW & REVERSE BRAKE DUTY SOLENOID (IN TRANSMISSION). 1) Remove the transmission connector from bracket. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the oil pan, and disconnect the connector from control valve body. 4) Measure the resistance between low & reverse duty solenoid connector and transmission ground. Connector & terminal (AT2) No. 1 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LOW & REVERSE DUTY SOLENOID. Measure the resistance of harness between low & reverse duty solenoid and transmission connector. Connector & terminal (T4) No. 6 (AT2) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND LOW & REVERSE DUTY SOLENOID. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 6 Transmission ground:
Repair open circuit of harness between low & reverse duty solenoid and transmission connector.
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair harness or connector in low & reverse duty solenoid and transmission.
Repair the short circuit of the harness between the low & reverse duty solenoid and the transmission connector.
4AT(diag)-73

U: DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

DTC DETECTING CONDITION: Shift lock solenoid malfunction, open or short reverse inhibitor control circuit TROUBLE SYMPTOM: Gear is shifted from N range to P range during driving at 20 km/h (12 MPH) or more. Gear cannot be shifted from N range to R range. WIRING DIAGRAM:
B280
B116
3 4 5 1 2 6 7 8 9 10 11 12
SHIFT LOCK SOLENOID

B116
B280
3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 27 28 29 30 21 22
E
AT-04340
Step CHECK SHIFT LOCK SOLENOID. 1) Start the integrated unit by force, and check the operation of shift lock solenoid. <Ref. to LAN(diag)-12, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.> 2) Operate AT select lever without depressing the brake pedal. CHECK OUTPUT SIGNAL OF INTEGRATED UNIT. 1) Display the following items using Subaru Select Monitor. Key-lock warning SW Shift Position P SW 'Stop Light Switch 2) Step on the brake and shift the AT select lever to P range. CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND SHIFT LOCK SOLENOID. Measure the harness resistance between the body integrated unit and chassis ground. Connector & terminal (B280) No. 6 Chassis ground:
Check Yes Does the AT select lever oper- Go to step 2. ate?
No Go to step 3.
Do the units of measure of items displayed change?
Go to step 3.
Check the circuits of the items whose values do not change.
Go to step 4.
Repair the short circuit of harness between body integrated unit and shift lock solenoid connector.
4AT(diag)-74

Step CHECK HARNESS BETWEEN SHIFT LOCK SOLENOID AND CHASSIS GROUND TERMINAL. Measure the resistance of harness between shift lock solenoid and chassis ground. Connector & terminal (B116) No. 4 Chassis ground: CHECK SHIFT LOCK SOLENOID. Measure the resistance of shift lock solenoid terminals. Connector & terminal (B116) No. 3 No. 4: CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Shift the AT select lever to D range. 4) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B280) No. 6 (+) Chassis ground (): CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Lift up the vehicle. 2) Start the engine. 3) Shift the select lever to D range and slowly increase vehicle speed to over 20 km/h (12 MPH). NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B280) No. 6 (+) Chassis ground (): CHECK POOR CONTACT. Check Yes Is the resistance less than 1 :? Go to step 5. No Repair the open circuit of harness between chassis ground and shift lock solenoid connector. Replace the shift lock solenoid.
Go to step 6.
Go to step 8.
Even if the ATF Go to step 8. temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in the reverse inhibitor control circuit.
Is there poor contact in the Repair the poor reverse inhibitor control circuit? contact.
Replace the body integrated unit. <Ref. to SL-56, Body Integrated Unit.>
4AT(diag)-75

V: DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL)

DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: No lock up or tight corner braking phenomenon is occurred. WIRING DIAGRAM:
AT13 B54 TCM 1 2 3 15 26 No.12 B11 B11 T4 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 9 17 13 1 2 3 1 2 AT13 B54 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
BATTERY
MAIN SBF SBF-6
IGNITION SWITCH
REAR VEHICLE SPEED SENSOR
AT-04341
Step Check Yes CHECK IGNITION POWER SUPPLY CIRIs the voltage 10 V or more? Go to step 2. CUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear vehicle speed sensor. 3) Turn the ignition switch to ON. 4) Measure the ignition power supply voltage between rear vehicle speed sensor connector and transmission ground. Connector & terminal (AT13) No. 3 (+) Transmission ground (): CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 3. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between TCM connector and rear vehicle speed sensor connector. Connector & terminal (B54) No. 15 (AT13) No. 1: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 4. TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and rear vehicle speed sensor connector. Connector & terminal (B54) No. 26 (AT13) No. 2:
No Check harness between rear vehicle speed sensor and battery for open circuit, short or poor contact. Repair the harness if required.
Repair the open circuit or poor contact of the connector in harness between TCM and rear vehicle speed sensor connector. Repair the open circuit or poor contact of the connector in harness between TCM and rear vehicle speed sensor connector.
4AT(diag)-76

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 15 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 26 Chassis ground: PREPARE OSCILLOSCOPE. CHECK INPUT SIGNAL FOR TCM. 1) Connect the connectors to TCM and transmission. 2) Lift up the vehicle. 3) Start the engine and set vehicle in 20 km/h (12 MPH) condition. NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Measure the AC voltage between TCM connector terminals. Connector & terminal (B54) No. 26 (+) No. 15 (): CHECK INPUT SIGNAL FOR TCM USING OSCILLOSCOPE. 1) Connect the connectors to TCM and transmission. 2) Lift up the vehicle. 3) Set the oscilloscope to TCM connector terminals. Connector & terminal Positive probe; (B54) No. 26: Ground lead; (B54) No. 15: 4) Start the engine and set vehicle in 20 km/h (12 MPH) condition. NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> 5) Measure the signal voltage indicated on oscilloscope. CHECK POOR CONTACT. Check Is the resistance 1 M: or more? Yes Go to step 5. No Repair the short circuit of harness between TCM and rear vehicle speed sensor connector. Repair the short circuit of harness between TCM and rear vehicle speed sensor connector. Go to step 7. Replace the rear vehicle speed sensor.
Go to step 6.
6 7
Do you have an oscilloscope? Is the voltage approx. 2 V or more?
Is the pulse voltage approx. 5 V? Go to step 9.
Replace the rear vehicle speed sensor.
Is there poor contact in rear vehicle speed sensor circuit?
4AT(diag)-77

W: DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION

DTC DETECTING CONDITION: Output signal circuit of transfer duty solenoid is open or shorted. TROUBLE SYMPTOM: Tight corner braking phenomenon occurs. Front wheel slips on the slippery road. WIRING DIAGRAM:
AT2
B54
TCM
1 2 3 4 5 6 7 8 9 10
B11 B11 8 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
AT 2
TRANSFER DUTY SOLENOID
B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
CONTROL VALVE BODY
AT-04774
4AT(diag)-78

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 5 (B11) No. 8: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure the resistance of harness connector between TCM and chassis ground. Connector & terminal (B54) No. 5 Chassis ground: CHECK TRANSFER DUTY SOLENOID. Measure the resistance between transmission connector and transmission terminals. Connector & terminal (T4) No. 8 No. 20: CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Connect the connectors to TCM and transmission. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON (engine OFF) and run the Subaru Select Monitor. 4) Shift the select lever to the N range, and fully close the throttle pedal. (Vehicle speed is 0 km/h (0 MPH)) 5) Read the data of AWD Duty Ratio using Subaru Select Monitor. Transfer duty solenoid is indicated in %. CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR. 1) Shift the select lever to D range. 2) Read the data of AWD Duty Ratio using Subaru Select Monitor. Transfer duty solenoid is indicated in %. Check Yes Is the resistance less than 1 :? Go to step 2. No Repair the open circuit of harness between TCM and transmission connector.
Go to step 3.
Is the value approx. 5%?
Go to step 5.
Go to step 6.
CHECK POOR CONTACT.
Is the measured value approx. Even if the ATF Go to step 6. 18 35%? temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in TCM and transmission. Is there poor contact in transfer Repair the poor Replace the TCM. duty solenoid circuit? contact. <Ref. to 4AT-61, Transmission Control Module (TCM).>
4AT(diag)-79

Step CHECK TRANSFER DUTY SOLENOID (IN TRANSMISSION). 1) Lift up the vehicle. 2) Drain the automatic transmission fluid. CAUTION: Do not drain ATF until it cools down. 3) Remove the extension case, and disconnect the connector from transfer duty solenoid. 4) Measure the resistance between transfer duty solenoid connector and transmission ground. Connector & terminal (AT2) No. 7 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN TRANSFER DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between transfer duty solenoid and transmission connector. Connector & terminal (T4) No. 8 (AT2) No. 7: CHECK HARNESS CONNECTOR BETWEEN TRANSFER DUTY SOLENOID AND TRANSMISSION. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 8 Transmission ground: Check Yes Is the resistance 2.0 6.0 :? Go to step 8. No Replace the control valve body. <Ref. to 4AT-56, Control Valve Body.>
Repair the open circuit of harness between transfer duty solenoid and transmission connector.
Even if the ATF temperature warning light blinks, the circuit is in normal condition at this time. A temporary poor contact of connector or harness may be the cause. Repair the harness or poor contact in the transfer duty solenoid and transmission.
Repair short circuit of the harness between the transfer duty solenoid and transmission connector.
X: DTC P1718 CAN COMMUNICATION CIRCUIT

NOTE: Refer to Body Integrated Unit for diagnosis of P1718. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
4AT(diag)-80

Y: DTC P1817 SPORT MODE SWITCH CIRCUIT

DTC DETECTING CONDITION: Input signal circuit of SPORT/manual mode switch is shorted. TROUBLE SYMPTOM: Manual mode can not be set. The SPORT indicator light does not illuminate. No SPORT mode occurs. WIRING DIAGRAM:
B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B: B280 BODY INTEGRATED UNIT C: B281
B20
B30
C26
C15
C25
C: B281 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 AT SELECT LEVER B116 B54
*1
*2
JOINT CONNECTOR B365
*1
*2
DOWN 10 6
SPORT/ MANUAL MODE SWITCH 8
UP
11
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
5 6 14 15 16 25 26 27 33 34 35
18
B54
TCM
17
B116
1 2 3 4 5 6 7 8 9 10 11 12
*1 *2
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AT-04343
Step Check CHECK BODY INTEGRATED UNIT. Is DTC displayed? 1) Connect the Subaru Select Monitor to data link connector. 2) Turn the ignition switch to ON. (engine OFF) 3) Read the DTC of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT INPUT Is OFF displayed? SIGNAL. 1) Shift the AT select lever to P range. 2) Read the Tiptronic Mode Switch data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.>
Yes No Perform the diag- Go to step 2. nosis according to DTC.
Go to step 3.
Go to step 7.
4AT(diag)-81

Step CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Shift the AT select lever from P to D range. 2) Read the Tiptronic Mode Switch data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Shift the AT select lever to SPORT mode. 2) Read the Tiptronic Mode Switch data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK INHIBITOR SWITCH. Shift the AT select lever from P to D range. Check Yes Is the indication on each range Go to step 4. OFF? No Replace the select lever assembly. <Ref. to CS-23, Select Lever.>
Is ON displayed?
Go to step 5.
Replace the select lever assembly. <Ref. to CS-23, Select Lever.>
Adjust the inhibitor switch and select cable. <Ref. to 4AT-46, ADJUSTMENT, Inhibitor Switch.> <Ref. to CS-32, ADJUSTMENT, Select Cable.> CHECK INPUT SIGNAL FROM TCM. Is the indication on each range Even if the ATF Replace the TCM. 1) Shift the AT select lever from P to D OFF? temperature warn- <Ref. to 4AT-61, range. ing light is blinking, Transmission Con2) Read the Tiptronic Mode Switch data of the circuit is in nor- trol Module the TCM using the Subaru Select Monitor. <Ref. mal condition. A (TCM).> to 4AT(diag)-16, OPERATION, Subaru Select temporary short Monitor.> circuit of connector or harness may be the cause. Repair the harness or connector. CHECK HARNESS BETWEEN BODY INTE- Is the resistance 1 M: or Go to step 8. Repair the short GRATED UNIT AND SPORT/MANUAL MODE more? circuit of harness SWITCH. between body inte1) Turn the ignition switch to OFF. grated unit and 2) Disconnect the harness connector from sport/manual body integrated unit and AT select lever. mode switch. 3) Measure the resistance between the body integrated unit and chassis ground. Connector & terminal (B281) No. 26 Chassis ground: CHECK SPORT SHIFT SWITCH. Is the resistance 1 M: or Check the body Replace the select 1) Shift the AT select lever to P range. more? integrated unit. lever assembly. 2) Measure the resistance of SPORT/manual <Ref. to CS-23, mode switch connector terminals. Select Lever.> Terminals No. 9 No. 8:
Is the indication of range position indicator light in combination meter synchronized with position of select lever?
Go to step 6.
4AT(diag)-82


A: CHECK FWD SWITCH
DIAGNOSIS: LED does not illuminate even with the fuse installed on FWD fuse holder. FWD signal circuit is open or shorted. WIRING DIAGRAM:
i106 i107
1 2 3 4
No. 5
AWD WARNING LIGHT
COMBINATION METER
B361 1 2 3 4 5 6 7 8 9 10 11 12 13 14
IGNITION SWITCH
i10
21
22
F108
WN WN
SBF-6
5 6 7 8 1 2 3 4 9 10 11 12 13 14 15 16 17 18
MAIN SBF
ON
ON
B365
CAN JOINT CONNECTOR CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
i106
BATTERY ON ON
* * * *
i107
i10
WN WN
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
A27
A26
B: B280 B: B280 BODY INTEGRATED UNIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A: B30
i84 B20
A:
B54 5 6 14 15 16 25 26 27 33 34 35
* *2
B365
* *2
A17 A18 A: TCM B10 B: B54 B55
CAN JOINT CONNECTOR
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B:
B55
B361
13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
THROUGH JOINT CONNECTOR
F108
11
A:
i84
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
RELAY HOLDER
FWD FUSE HOLDER
F27
F27
1
* *1 *2
3 4 5 6 7 9 14 15 16 17
2 18 19 20 21 22
10 11
12 13
AT-04899
4AT(diag)-83

Step CHECK SPARE FUSE. CHECK FWD FUSE HOLDER. Connect the Subaru Select Monitor to data link connector. CHECK COMBINATION METER. Check Is the spare fuse OK? When the fuse is inserted to FWD fuse holder, does the LED illuminate? Does the AWD warning light illuminate? Yes Go to step 2. Go to step 3. No Replace the fuse. Go to step 4.
1 2
10
Go to INSPECGo to step 9. TION FOR SPORT/MANUAL MODE SWITCH. <Ref. to 4AT(diag)86, CHECK SPORT SHIFT SWITCH, Diagnostic Procedure without Diagnostic Trouble Code (DTC).> CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 5. Repair the open TCM AND FWD FUSE HOLDER. circuit of harness 1) Turn the ignition switch to OFF. between TCM and 2) Disconnect the connector from TCM. FWD fuse holder. 3) Measure the resistance of harness between TCM and FWD fuse holder. Connector & terminal (B55) No. 10 (F27) No. 8: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 6. Repair the open FWD FUSE HOLDER AND CHASSIS circuit of harness GROUND. between FWD fuse Measure the resistance of harness between holder and chassis FWD fuse holder and chassis ground. ground. Connector & terminal (F27) No. 9 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 7. Repair the short TCM AND FWD FUSE HOLDER. more? circuit of harness Measure the resistance of harness connector between TCM and between TCM and body to make sure that cirFWD fuse holder. cuit does not short. Connector & terminal (B55) No. 10 Chassis ground: CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 8. Go to step 10. 1) Turn the ignition switch to OFF. 2) Connect the connector to TCM. 3) Turn the ignition switch to ON. 4) Measure the signal voltage for TCM with the fuse installed to FWD fuse holder. Connector & terminal (B55) No. 10 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Is the voltage 10.5 V or more? Go to step 9. Replace the TCM. Measure the signal voltage for TCM with the <Ref. to 4AT-61, Transmission Confuse removed from FWD fuse holder. trol Module Connector & terminal (B55) No. 10 (+) Chassis ground (): (TCM).> CHECK BODY INTEGRATED UNIT. Is DTC of CAN communication Perform the diag- Go to step 10. nosis according to displayed? Check DTC of body integrated unit. DTC. CHECK COMBINATION METER. Is the AWD warning light OK? Go to step 11. Replace the comCheck the AWD warning light. <Ref. to IDI-5, bination meter INSPECTION, Combination Meter System.> assembly. <Ref. to IDI-22, Combination Meter.>
4AT(diag)-84

Step CHECK POOR CONTACT. Check Is there poor contact in FWD switch circuit? Yes Repair the poor contact. No Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).>
11
4AT(diag)-85

B: CHECK SPORT SHIFT SWITCH

DIAGNOSIS: Input signal circuit of SPORT/manual mode switch is open or shorted. TROUBLE SYMPTOM: Does not shift on manual mode. WIRING DIAGRAM:
B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B30
B20
C26
C15
C25
C: B281 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 AT SELECT LEVER B116 B54
*1
*2
*1
*2
DOWN 10 6
SPORT/ MANUAL MODE SWITCH 8
UP
11
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
5 6 14 15 16 25 26 27 33 34 35
18
B54
TCM
17
B116
1 2 3 4 5 6 7 8 9 10 11 12
*1 *2
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AT-04343
4AT(diag)-86

Step Check CHECK SPORT SHIFT SWITCH. Is ON displayed? 1) Move the AT select lever to SPORT mode. 2) Shift and hold the AT select lever to up side. 3) Read the Up Switch data of the TCM using the Subaru Select Monitor. <Ref. to 4AT(diag)17, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> CHECK SPORT SHIFT SWITCH. Is ON displayed? 1) Shift and hold the AT select lever to down side. 2) Read the Down Switch data of TCM using Subaru Select Monitor. Yes Go to step 2. No Go to step 3.
CHECK BODY INTEGRATED UNIT. 1) Turn the ignition switch to ON. 2) Shift and hold the AT select lever to up side. 3) Read the TIP UP SW input data of body integrated unit using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Check DTC of body integrated unit. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK GROUND CIRCUIT OF SPORT/MANUAL MODE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from SPORT/ manual mode switch. 3) Measure the resistance of harness between SPORT/manual mode switch connector and chassis ground. Connector & terminal (B116) No. 6 Chassis ground: CHECK SPORT/MANUAL MODE SWITCH. Measure the resistance between SPORT/manual mode switch terminals. Connector & terminal (B116) No. 6 No. 7: CHECK SPORT/MANUAL MODE SWITCH. 1) Shift and hold the AT select lever to up side. 2) Measure the resistance between SPORT/ manual mode switch terminals. Connector & terminal (B116) No. 6 No. 7:
Is ON displayed?
Go to the proceGo to step 12. dure CHECK SPORT SHIFT INDICATOR. <Ref. to 4AT(diag)90, CHECK SPORT SHIFT INDICATOR, Diagnostic Procedure without Diagnostic Trouble Code (DTC).> Go to step 4. Go to step 5.
Is DTC of CAN communication Perform the diag- Inspect the TCM. displayed? nosis according to DTC. Is the resistance less than 1 :? Go to step 6. Repair the open circuit of harness between SPORT/ manual mode switch and chassis ground.
Go to step 7.
Replace the guide plate assembly.
Replace the guide plate assembly.
4AT(diag)-87

Step CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND SPORT/ MANUAL MODE SWITCH. 1) Disconnect the connector from body integrated unit. 2) Measure the resistance of harness between body integrated unit connector and SPORT/ manual mode switch connector. Connector & terminal (B116) No. 7 (B281) No. 15: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND SPORT/ MANUAL MODE SWITCH. Measure the resistance of harness between SPORT/manual mode switch connector and chassis ground. Connector & terminal (B116) No. 7 Chassis ground: CHECK INPUT SIGNAL TO BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Turn the ignition switch to ON (engine OFF). 3) Check the signal voltage for body integrated unit. Connector & terminal (B281) No. 15 (+) Chassis ground (): CHECK INPUT SIGNAL TO BODY INTEGRATED UNIT. 1) Shift and hold the AT select lever to shift up side. 2) Check the signal voltage for body integrated unit. Connector & terminal (B281) No. 15 (+) Chassis ground (): CHECK BODY INTEGRATED UNIT. 1) Turn the ignition switch to ON. 2) Shift and hold the AT select lever to down side. 3) Read the TIP DOWN SW input data of body integrated unit using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Check DTC of body integrated unit. Check Yes Is the resistance less than 1 :? Go to step 9. No Repair the open circuit of harness between the SPORT/manual mode switch connector and body integrated unit connector, or poor contact of connector. Repair the short circuit of harness between SPORT/ manual mode switch connector and body integrated unit connector. Replace the body integrated unit.
Go to step 10.
10
Is the voltage 1.5 8 V?
Go to step 11.
11
Go to step 21.
12
Is ON displayed?
Go to step 13.
Go to step 14.
13
14
15
Is DTC of CAN communication Perform the diag- Inspect the TCM. displayed? nosis according to DTC. CHECK GROUND CIRCUIT OF SPORT/MAN- Is the resistance less than 1 :? Go to step 15. Repair the open UAL MODE SWITCH. circuit of harness 1) Turn the ignition switch to OFF. between SPORT/ 2) Disconnect the connector from SPORT/ manual mode manual mode switch. switch and chassis 3) Measure the resistance of harness between ground. SPORT/manual mode switch connector and chassis ground. Connector & terminal (B116) No. 10 (+) Chassis ground: Go to step 16. Replace the guide Is the resistance 1 M: or CHECK SPORT/MANUAL MODE SWITCH. plate assembly. Measure the resistance between SPORT/man- more? ual mode switch terminals. Connector & terminal (B116) No. 10 No. 11:
4AT(diag)-88

Step CHECK SPORT/MANUAL MODE SWITCH. 1) Shift and hold the AT select lever to down side. 2) Measure the resistance between SPORT/ manual mode switch terminals. Connector & terminal (B116) No. 10 No. 11: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND SPORT/ MANUAL MODE SWITCH. 1) Disconnect the connector from body integrated unit. 2) Measure the resistance of harness between body integrated unit connector and SPORT/ manual mode switch connector. Connector & terminal (B116) No. 11 (B281) No. 25: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND SPORT/ MANUAL MODE SWITCH. Measure the resistance of harness between SPORT/manual mode switch connector and chassis ground. Connector & terminal (B116) No. 11 Chassis ground: CHECK INPUT SIGNAL TO BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Turn the ignition switch to ON (engine OFF). 3) Check the signal voltage for body integrated unit. Connector & terminal (B281) No. 25 (+) Chassis ground (): CHECK INPUT SIGNAL TO BODY INTEGRATED UNIT. 1) Shift and hold the AT select lever to down side. 2) Check the signal voltage for body integrated unit. Connector & terminal (B281) No. 25 (+) Chassis ground (): CHECK POOR CONTACT. Check Yes Is the resistance less than 1 :? Go to step 17. No Replace the guide plate assembly.
16
17
18
Go to step 19.
19
Is the voltage 1.5 8 V?
Go to step 20.
Repair the open circuit of harness between the SPORT/manual mode switch connector and body integrated unit connector, or poor contact of connector. Repair the short circuit of harness between SPORT/ manual mode switch connector and body integrated unit connector. Go to step 21.
20
Go to step 21.
Replace the body integrated unit. <Ref. to 4AT-61, Transmission Control Module (TCM).>
21
Is there poor contact in the SPORT/manual mode switch circuit?
Temporary poor contact of the SPORT/manual mode switch circuit connector or harness.
4AT(diag)-89

C: CHECK SPORT SHIFT INDICATOR

DIAGNOSIS: Output signal circuit of SPORT shift indicator is open or shorted. TROUBLE SYMPTOM: SPORT shift indicator does not display or remains displayed. SPORT shift indicator display does not change. WIRING DIAGRAM:
i106 3 i107
No. 5
LCD (SPORT SHIFT)

COMBINATION METER
1 2 3 4
IGNITION SWITCH
i10
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
WN WN
SBF-6
21
22
MAIN SBF
ON
ON
i10
CAN JOINT CONNECTOR
* *
CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
i106
BATTERY ON ON
i107
WN WN
* *
A:
i84
A27
A26 i84 B: B280
A:
*2 *2
*1 *1
CAN JOINT CONNECTOR
B365 B54 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
* *1 *2
B54
18
TCM
17
AT-04900
4AT(diag)-90

Check Yes No Is DTC of CAN communication Perform the diag- Go to step 2. displayed? nosis according to DTC. CHECK TCM. Is the gear position 2? Go to step 3. Replace the TCM. 1) Turn the ignition switch to OFF. <Ref. to 4AT-61, 2) Connect the Subaru Select Monitor to data Transmission Conlink connector. trol Module 3) Turn the ignition switch to ON. (engine OFF) (TCM).> 4) Run the Subaru Select Monitor. 5) Shift the AT select lever to SPORT mode. 6) Shift up the AT select lever. 7) Read the Gear Position data of TCM using Subaru Select Monitor. Is the gear position 1? Go to step 4. Replace the TCM. CHECK TCM. <Ref. to 4AT-61, 1) Shift down the AT select lever. 2) Read the Gear Position data of TCM using Transmission ConSubaru Select Monitor. trol Module (TCM).> CHECK BODY INTEGRATED UNIT. Is the SPORT shift gear posi- Go to step 5. Check the body Read the data of SPORT shift gear position tion 2? integrated unit. using Subaru Select Monitor. CHECK COMBINATION METER. Is the SPORT shift indicator Check the buzzer. Replace the com<Ref. to IDI-5, INSPECTION, Combination OK? <Ref. to 4AT(diag)- bination meter Meter System.> 92, CHECK assembly. <Ref. to BUZZER, DiagIDI-22, Combinanostic Procedure tion Meter.> without Diagnostic Trouble Code (DTC).> Step CHECK BODY INTEGRATED UNIT. Check DTC of body integrated unit.
4AT(diag)-91

D: CHECK BUZZER
DIAGNOSIS: Output signal circuit of buzzer is open or shorted. TROUBLE SYMPTOM: Buzzer remains beeping. WIRING DIAGRAM:
i106 3 i107
No. 5
BUZZER (SPORT SHIFT)

1 2 3 4
COMBINATION METER
IGNITION SWITCH
i10
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
WN WN
SBF-6
21
22
MAIN SBF
ON
ON
i10
CAN JOINT CONNECTOR
* *
CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
i106
BATTERY ON ON
i107
WN WN
* *
A:
i84
A27
A26 i84 B: B280
A:
*2 *2
*1
CAN JOINT CONNECTOR
*1
B365 B54 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
* *1 *2
B54
18
TCM
17
AT-04901
4AT(diag)-92

Step Check CHECK BODY INTEGRATED UNIT. Is the SPORT shift buzzer dis1) Turn the ignition switch to OFF. play ON? 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. (engine OFF) 4) Run the Subaru Select Monitor. 5) Read the data of SPORT shift (buzzer) of body integrated unit using Subaru Select Monitor. CHECK COMBINATION METER. Is the buzzer OK? <Ref. to IDI-5, INSPECTION, Combination Meter System.> Yes No Replace the TCM. Go to step 2. <Ref. to 4AT-61, Transmission Control Module (TCM).>
Refer to Symptom Related Diagnostic. <Ref. to 4AT(diag)-94, General Diagnostic Table.>
Replace the combination meter assembly. <Ref. to IDI-22, Combination Meter.>
4AT(diag)-93


A: INSPECTION
Symptom Problem parts Inhibitor switch Starter does not operate when select lever is in P or N Select cable range. Starter operates when select lever is in R or D range. AT select lever Starter motor and harness Strainer Transfer duty solenoid Abnormal noise when select lever is in P or N. Oil pump Drive plate ATF level too high or too low Strainer Hissing noise occurs during standing start. ATF level too high or too low Noise occurs while driving in D1. Final gear Planetary gear Reduction gear Noise occurs while driving in D2. Differential gear oil level too high or too low Final gear Low & reverse brake Noise occurs while driving in D3. Reduction gear Differential gear oil level too high or too low Final gear Low & reverse brake Noise occurs while driving in D4. Planetary gear Reduction gear Differential gear oil level too high or too low Select cable Inhibitor switch Vehicle moves when select lever is in N range. TCM Low clutch Accelerator pedal position sensor ATF temperature sensor Line pressure linear solenoid Low clutch duty solenoid Shock occurs when select lever is shifted from N to D range. Low clutch TCM Harness Control valve ATF deterioration Control valve Low clutch Excessive time lag occurs when select lever is shifted from N Line pressure linear solenoid to D range. Seal ring Front gasket of transmission case Accelerator pedal position sensor ATF temperature sensor Line pressure linear solenoid Shock occurs when select lever is shifted from N to R range. TCM Harness Control valve ATF deterioration Control valve Low & reverse clutch Excessive time lag occurs when the select lever is shifted from Reverse clutch Line pressure linear solenoid N to R range. Seal ring Front gasket of transmission case
4AT(diag)-94

Symptom Vehicle does not start in any shift range. (Engine stalls) Problem parts Parking brake mechanism Planetary gear Strainer Line pressure linear solenoid Control valve Drive pinion Hypoid gear Axle shaft Differential gear Oil pump Input shaft Output shaft Planetary gear Drive plate ATF level is too low Front gasket of transmission case Select cable AT select lever Line pressure linear solenoid Control valve Low & reverse clutch Reverse clutch Low clutch 2-4 brake Planetary gear Parking brake mechanism Low clutch One-way clutch Reverse clutch Control valve Control valve Low clutch Reverse clutch ATF level is too low ATF deterioration Front gasket of transmission case Differential gear oil level too high or too low Oil pump Torque converter one-way clutch Engine performance TCM Control valve High clutch 2-4 brake Planetary gear Control valve High clutch 2-4 brake Planetary gear TCM Rear vehicle speed sensor Front vehicle speed sensor Accelerator pedal position sensor Control valve 2-4 brake TCM Control valve High clutch
Vehicle does not start in any shift range. (Engine operates)
Vehicle does not start in R range only. (Engine operates)
Vehicle does not start in R range only. (Engine stalls)
Vehicle does not start in D range. (Engine operates) Vehicle does not start in D range. (Engine stalls) Vehicle does not start in R range only. (Engine operates)
Acceleration during standing start is poor. (High rpm stall)
Acceleration during standing start is poor. (Low rpm stall)
Acceleration is poor when select lever is in D range. (Normal rpm stall)
Acceleration is poor when select lever is in R range. (Normal rpm stall)
No shift occurs from 1st to 2nd gear.
No shift occurs from 2nd to 3rd gear.
4AT(diag)-95

Symptom No shift occurs from 3rd to 4th gear. Problem parts TCM ATF temperature sensor Control valve 2-4 brake Inhibitor switch TCM Accelerator pedal position sensor Control valve Control valve Control valve Low & reverse brake Inhibitor switch TCM Front vehicle speed sensor Rear vehicle speed sensor Accelerator pedal position sensor Control valve Ground TCM Accelerator pedal position sensor ATF temperature sensor Control valve Lock-up facing Engine speed signal Select cable AT select lever Parking mechanism ATF level too high Differential gear oil level too high Seal pipe Double oil seal High clutch 2-4 brake Low & reverse clutch Reverse clutch Lock-up facing ATF deterioration TCM Torque converter turbine speed sensor Accelerator pedal position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure linear solenoid Control valve 2-4 brake ATF deterioration Engine performance Low & reverse duty solenoid TCM Accelerator pedal position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure linear solenoid Control valve 2-4 brake
Engine brake is not effected when select lever is shifted from 4th gear to 3rd gear. Engine brake is not effected when select lever is shifted from 3rd gear to 2nd gear. Engine brake is not effected when select lever is shifted from 2nd gear to 1st gear.
Shift characteristics are erroneous.
No lock-up occurs.
Parking brake does not function. Shift lever cannot be moved or is hard to move from P range. ATF spurts out. Differential oil spurts out. Differential oil level changes excessively.
Odor is produced from ATF supply pipe.
Shock occurs when shifting from 1st to 2nd gear.
Slippage occurs when shifting from 1st to 2nd gear.
4AT(diag)-96

Symptom Problem parts TCM Torque converter turbine speed sensor Accelerator pedal position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure linear solenoid Low & reverse duty solenoid Control valve High clutch 2-4 brake ATF deterioration Engine performance High clutch duty solenoid TCM Accelerator pedal position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure linear solenoid Control valve High clutch 2-4 brake Low & reverse duty solenoid TCM Torque converter turbine speed sensor Accelerator pedal position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure linear solenoid Control valve Low clutch duty solenoid 2-4 brake ATF deterioration Engine performance TCM Accelerator pedal position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure linear solenoid Control valve 2-4 brake TCM Torque converter turbine speed sensor Accelerator pedal position sensor ATF temperature sensor Line pressure linear solenoid Control valve 2-4 brake duty solenoid 2-4 brake ATF deterioration High clutch duty solenoid TCM Torque converter turbine speed sensor Accelerator pedal position sensor ATF temperature sensor Line pressure linear solenoid Control valve Low & reverse clutch ATF deterioration 2-4 brake duty solenoid Low & reverse brake duty solenoid
Shock occurs when shifting from 2nd to 3rd gear.
Slippage occurs when shifting from 2nd to 3rd gear.
Shock occurs when shifting from 3rd to 4th gear.
Slippage occurs when shifting from 3rd to 4th gear.
Shock occurs when shifting from 3rd to 2nd gear.
Shock occurs when shifting from 2nd to 1st gear.
4AT(diag)-97

Symptom Problem parts TCM Accelerator pedal position sensor ATF temperature sensor Line pressure linear solenoid Control valve Lock-up damper Engine performance TCM Lock-up duty solenoid Lock-up facing Lock-up damper TCM Front vehicle speed sensor Rear vehicle speed sensor Accelerator pedal position sensor ATF temperature sensor Transfer clutch Transfer valve Transfer duty solenoid ATF deterioration Harness TCM Front vehicle speed sensor Accelerator pedal position sensor ATF temperature sensor Control valve Transfer clutch Transfer valve Transfer pipe Transfer duty solenoid TCM Transfer clutch Transfer valve Transfer duty solenoid Fuse Select cable AT select lever Detent spring Manual plate Detent spring Manual plate Select cable AT select lever Detent spring Manual plate SPORT/manual mode switch TCM Body integrated unit Up shift switch Down shift switch TCM Body integrated unit Tire size Tire pressure TCM FWD fuse holder Harness
Shock occurs when accelerator pedal is released from medium speed.
Vibration occurs during straight-forward operation.
Vibration occurs during turns. (Tight corner braking phenomenon)
Front wheel slippage occurs during standing starts.
It is not set in FWD mode.
Select lever is hard to move. Select lever is excessively hard to move. (Unreasonable resistance) Select lever slips out of selected shift position during acceleration or while driving on rough terrain.
Manual mode can not be set.
Gear does not change though the select lever is operated in manual mode.
AWD warning light remains blinking or illuminated.
4AT(diag)-98
General Description
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
Model Type Stall torque ratio Nominal diameter Stall speed (at sea level) One-way clutch Turbo Non-turbo Symmetric, 3 element, single stage, 2 phase torque converter 2.0 1.9 246 mm (9.69 in) 2,300 3,200 1,900 2,200 rpm rpm Sprag type one-way clutch
5. PLANETARY GEAR AND PLATE

Model Number of front internal gear teeth Number of front carrier teeth Number of front sun gear teeth Number of mid internal gear teeth Number of mid carrier teeth Number of mid sun gear teeth Number of rear internal gear teeth Number of rear carrier teeth Number of rear sun gear teeth Number of front brake drive plates Number of input clutch drive plates Number of high & low reverse clutch drive plates Number of direct clutch drive plates Number of reverse brake drive plates Number of forward brake drive plates 6 4 5 5 5 4 Turbo 106 28 50 78 18 42 110 24 62 2 5 Nonturbo
2. OIL PUMP
Type Driving method Number of teeth Internal gear fixed displacement pump Driven by engine Inner rotor 9 Outer rotor 10
3. TRANSMISSION CONTROL ELEMENT

Type Multi-plate clutch Multi-plate brake One-way clutch (sprague type) 5-forward, 1-reverse, double-row planetary gears 3 sets 3 sets 2 sets
6. SELECTOR POSITION
P (Park) R (Reverse) N (Neutral) D (Drive) Transmission is in neutral, output member is immovable, engine start is possible Transmission is in reverse. Transmission is in neutral and engine start is possible Automatic gear change 1st m o 2nd m o 3rd m o 4th m o 5th Manual gear change 1sto 2ndo 3rdo 4tho 5th Manual gear change 1st m 2nd m 3rd m 4th m 5th Wire cable type
4. TRANSMISSION GEAR RATIO

1st 2nd 3rd 4th 5th Rev. 3.540 2.264 1.471 1.000 0.834 2.370 Manual mode (+) Manual mode () Control method
5AT-2
General Description
7. HYDRAULIC CONTROL AND LUBRICATION

Electronic/hydraulic control [5 forward gear changes made by electronic signals of vehicle speed and accelerator (throttle) opening] Recommended materials SUBARU ATF HP Idemitsu ATF HP CAUTION: Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble.
8. COOLING AND HARNESS

Liquid-cooler incorporated in radiator Transmission harness 20 + 8 poles Cooling system
Type
9. TRANSFER
Transfer type Number of transfer clutch drives and driven plates Reduction gear ratio Variable torque distribution (VTD) 3 1.000 (41/41)
Fluid Alternative
10.FINAL REDUCTION GEAR

Model Front final reduction gear ratio 3.0 R LTD OBK 2.5 XT LTD OBK 3.0 R 3.272 2.5 GT 2.5 GT LTD 3.0 R 3.083
Fluid capacity
9.6 10.0 2 (US qt, Imp qt) (10.1 10.6, 8.4 8.8) Forced feed lubrication with Lubrication system oil pump
11.RECOMMENDED GEAR OIL

(1) (2) (3) GL-5 (4) -30 -26 -15 -5 0 -22 -15 5 23 32 85W 80W 75W -90 MT-00001
( C) ( F)
15 59
25 30 77 86 90
Lubrication oil
(1) Item (2) Front differential gear oil Front differential oil capacity 2 (US qt, Imp qt)
(3) API standard (4) SAE viscosity No. and applicable temperature 1.3 1.5 (1.4 1.6, 1.1 1.3)
5AT-3
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH & TRANSMISSION ASSEMBLY
(13) (14) (29) (28)
(33) T5 (5) (15) (4) T3 (32) (31) (16) (34) (8) (17) (1) (2) (3) (22) (19) (20) T1 (24) (6) (7) (30) (11) (10) (12) (25) (26) (27) T2 (9) T6 (21) (18) (23) T4 (17)
T7
T3
AT-04325
5AT-4
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) Torque converter ASSY Circlip Oil pump shaft Differential oil level gauge Pitching stopper bracket Differential oil drain plug Gasket Oil seal Lock plate Side retainer O-ring Oil seal ATF level gauge O-ring Oil charge pipe (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) O-ring Gasket Union screw Ball Spring Union screw ATF outlet pipe ATF inlet pipe Magnet Oil pan Gasket ATF drain plug Breather hose Nipple (30) (31) (32) (33) (34) O-ring Oil seal Dust cover Floating bracket Turbine speed sensor 1
Tightening torque:Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 20 (2.0, 14.8) T3: 25 (2.5, 18.4) T4: 40 (4.1, 29.5) T5: 41 (4.2, 30.2) T6: 45 (4.6, 33.2) T7: 70 (7.1, 51.6)
5AT-5
General Description
2. OIL PUMP & FRONT BRAKE
(9) (6) (22)
(21) (7) (4) (3) (2) (1) (8) (5) T2 (18) (2)
T1
(15) (14) (13) (12) (11) (17) (19) (20)
(10)
(16)
AT-03806
(1) (2) (3) (4) (5) (6) (7) (8) (9)
O-ring Washer Oil pump housing Oil pump rotor O-ring Air breather hose Oil pump cover O-ring Nipple
(10) (11) (12) (13) (14) (15) (16) (17) (18)
Needle bearing D-ring (Inner) D-ring (Outer) Front brake piston Return spring Retainer Snap ring Driven plate Drive plate
(19) (20) (21) (22)
Retainer plate Snap ring Stator shaft Needle bearing
5AT-6
General Description
3. FRONT PLANETARY CARRIER AND MIDDLE & REAR PLANETARY CARRIER

(4) (5)
(3)
(2)
(1)
(9)
(8) (7) (6) (17) (16) (15) (14) (13) (12) (11) (10)
(20) (19) (18)
AT-03006
(1) (2) (3) (4) (5) (6) (7)
Thrust bearing Front sun gear ASSY Snap ring Front carrier ASSY Race bearing O-ring Seal ring
(8) (9) (10) (11) (12) (13) (14)
Thrust bearing Input clutch ASSY Rear internal gear ASSY Thrust bearing Middle carrier ASSY Thrust bearing Race bearing
(15) (16) (17) (18) (19) (20)
Rear carrier ASSY Thrust bearing Middle & rear sun gear ASSY Washer Thrust bearing Seal ring
5AT-7
General Description
4. DIRECT CLUTCH AND HIGH & LOW REVERSE CLUTCH
(3)
(2)
(1)
AT-02018
(1)
Thrust bearing
(2)
High & low reverse clutch ASSY
(3)
Direct clutch ASSY
5AT-8
General Description
5. REVERSE BRAKE
(4)
(13) (3) (2) (1)
(5)
(12) (11) (10) (9) (8) (7) (6)
AT-03007
(1) (2) (3) (4) (5)
Snap ring Retainer plate Leaf spring Drive plate Driven plate
(6) (7) (8) (9)
Dish plate Snap ring Retainer Leaf spring
(10) (11) (12) (13)
Reverse brake piston D-ring (Outer) D-ring (Inner) AT main case
5AT-9
General Description
6. SHORT AT ASSEMBLY
(1)
(4) (3) (2)
AT-04385
(1)
Short AT ASSY (Non-disassembled)
(2) (3)
Thrust bearing Seal ring
(4)
Thrust bearing
5AT-10
General Description
7. CONTROL VALVE & TRANSMISSION HARNESS

(1) T
T (3) (4) (5)
(2)
(6)
AT-04215
(1) (2) (3)
Rear vehicle speed sensor Transmission harness ASSY Front vehicle speed sensor
(4) (5) (6)
Harness bracket Clip Control valve ASSY
5AT-11
General Description
8. DIFFERENTIAL GEAR
(1) (7) (13) (12) (14) (12) T1 (8) (4) (2) (3) (5) (6) (9) (10) T2 (1) (14) (13)
(11) (5) (3) (15) (4) T1
AT-03807
(1) (2) (3) (4) (5) (6) (7)
Lock plate Differential side retainer RH O-ring Oil seal Taper roller bearing Hypoid driven gear Drive pinion shaft
(8) (9) (10) (11) (12) (13)
Pinion shaft Straight pin Differential case RH Differential case LH Differential bevel gear Washer
(14) (15)
Differential bevel pinion Differential side retainer LH
Tightening torque:Nm (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 70 (7.1, 51.6 )
5AT-12
General Description
9. TRANSFER CASE, EXTENSION CASE & REDUCTION GEAR

(11) (15) (8) (6) (5) (13) (12) (7) (4) (3) (2) (1) (21) (20) (40) (23) (22) (41) (24) (42) (25) (10) (27) (26) (28) (30) (29) (9) (14) (31)
(19)
(38) (49)
(18) (17) (16) (36) (39) (35) (34) (33) (37)
(47) (45) (44) (48) (43) (46)
(32)
AT-03533
5AT-13
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Seal ring Reduction gear shim Ball bearing Snap ring Planetary pinion washer Needle bearing Spacer Pinion gear Washer Planetary carrier ASSY Planetary pinion shaft ASSY Snap ring Thrust bearing Intermediate shaft Thrust washer Rear drive shaft Ball bearing (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) Transfer clutch hub Transfer clutch plate Driven plate No. 3 Ball bearing Rear drive shaft shim Revolution gear Snap ring Clutch spring retainer Return spring Spring retainer Pressure plate Ball bearing O-ring D-ring Drive pinion shaft Ball bearing (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) (47) (48) (49) Reduction driven gear Snap ring Ball bearing Shim Shim Extension case Transmission hanger Oil seal Dust cover Taper roller bearing Drive pinion shim Oil seal Drive pinion collar O-ring Lock nut O-ring
5AT-14
General Description
10.TRANSMISSION CONTROL DEVICE & PARKING SUPPORT

(17) (16) T3 (1) (15) T3 (14) (2) (13)
(3) (12)
T4
(11) (10) (9)
(5) (4)
T1 (8) (6) (7)
T2
AT-03872
(1) (2) (3) (4) (5) (6) (7) (8)
Bracket Floating bracket AT main case Range select lever Straight pin Detent spring Manual plate Parking rod
(9) (10) (11) (12) (13) (14) (15) (16)
Parking support actuator Parking pawl shaft Return spring Parking pawl Ball bearing Snap ring Parking gear Reduction driven gear
(17)
Ball bearing
Tightening torque:Nm (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 7 (0.7, 5.2) T3: 25 (2.5, 18.4) T4: <Ref. to 5AT-79, Parking Pawl.>
5AT-15
General Description
11.TRANSMISSION CONTROL MODULE
(2)
T2
T1 T1
(3)
(1)
AT-04381
(1) (2)
Transmission control module (TCM) Relay
(3)
Lateral G sensor
5AT-16
General Description
T2 (2)
T2
(3)
T4 (1)
T5
(4)
T3 T1
T5 AT-04382
(1) (2) (3) (4)
Pitching stopper Rear cushion rubber Crossmember Stopper
5AT-17
General Description
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Until the oil pan is removed, do not place with the oil pan side facing up to prevent foreign matter from entering the valve body. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, disassembly and replacement. When disassembling the case and other light alloy parts, disassemble them by slightly tapping with a plastic hammer. Do not pry apart with screwdrivers or other tools. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine gear oil, grease or equivalent. Do not mix them of different grades or manufacturers. Be sure to tighten bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Apply gear oil onto sliding or revolving surfaces before installation. Replace deformed or damaged snap rings with new parts. Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. Avoid damaging the mating surface of the case. Before applying liquid gasket, completely remove the old liquid gasket.
5AT-18
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 498575400 DESCRIPTION OIL PRESSURE GAUGE ASSY REMARKS Used for measuring oil pressure.
ST-498575400
498897200
OIL PRESSURE ADAPTER
Used together with oil pump cover installed on when measuring line pressure.
ST-498897200
498897800
OIL PRESSURE ADAPTER SET
Used for measuring transfer clutch pressure.
ST-498897800
498545400
OIL FILTER WRENCH
Used for removing and installing the ATF filter.
ST-498545400
5AT-19
General Description
ILLUSTRATION TOOL NUMBER 498277200 DESCRIPTION STOPPER SET REMARKS Used for removing and installing automatic transmission assembly to engine. Used for preventing the torque converter from falling.
ST-498277200
41099AC000
ENGINE SUPPORT ASSY
Used for supporting engine.
ST41099AC000
41099AA010
ENGINE SUPPORT BRACKET
ST41099AA010
41099AA020
ENGINE SUPPORT
ST41099AA020
398527700
PULLER ASSY
Used for removing the extension case roller bearing. Used for removing the extension oil seal. Used for removing the front differential side retainer bearing outer race. Used for removing the front differential side retainer oil seal.
ST-398527700
5AT-20
General Description
ILLUSTRATION TOOL NUMBER 498057300 DESCRIPTION INSTALLER REMARKS Used for installing the extension oil seal.
ST-498057300
498077000
REMOVER
ST-498077000
18630AA010
Used for removing and installing the differential side retainer.
ST18630AA010
398487700
DRIFT
Used for installing the front differential taper roller bearing.
ST-398487700
498255400
PLATE
Used for measuring the backlash of hypoid gear.
ST-498255400
5AT-21
General Description
ILLUSTRATION TOOL NUMBER 498247001 DESCRIPTION MAGNET BASE REMARKS Used for measuring the gear backlash. Used together with DIAL GAUGE (498247100).
ST-498247001
498247100
DIAL GAUGE
Used for measuring the gear backlash. Used together with MAGNET BASE (498247001).
ST-498247100
498517000
REPLACER
Used for removing the front roller bearing.
ST-498517000
499787700
WRENCH
ST-499787700
398643600
GAUGE
Used for measuring total end play, extension end play and drive pinion height.
ST-398643600
5AT-22
General Description
ILLUSTRATION TOOL NUMBER 398744300 DESCRIPTION PISTON GUIDE REMARKS Used for measuring height from mating surface of the main case to pressure plate.
ST-398744300
499737100
PULLER SET
Used for removing the reduction driven gear assembly.
ST-499737100
498077600
REMOVER
Used for removing the ball bearing.
ST-498077600
18667AA010
HOLDER
Used for removing and installing the drive pinion lock nut. Used as a handle to rotate gear when checking tooth contact.
ST18667AA010
1B022XU0
ST1B022XU0
5AT-23
General Description
ILLUSTRATION TOOL NUMBER 18675AA000 DESCRIPTION DIFFERENTIAL SIDE OIL SEAL INSTALLER REMARKS Used for installing the differential side retainer oil seal.
ST18675AA000
18654AA000
INSTALLER
Used for removing and installing the ball bearing.
ST18654AA000
28399SA010
OIL SEAL PROTECTOR
Used for protecting oil seal when installing front drive shaft.
ST28399SA010
18763AA000
COMPRESSOR SHAFT
Used for disassembling multi-plate clutch for shift transmission.
ST18763AA000
18765AA000
COMPRESSOR SUPPORT
ST18765AA000
5AT-24
General Description
ILLUSTRATION TOOL NUMBER 18676AA020 DESCRIPTION TORX WRENCH REMARKS Used for disassembling torque converter case.
ST18676AA020
18854AA000
ANGLE GAUGE
Used for tightening parking support.
ST18854AA000
498077300
REMOVER
Used for removing ball bearing of reduction driven gear.
ST-498077300
499587100
OIL SEAL INSTALLER
Used for installing the oil seal.
ST-499587100
499787500
ADAPTER
Used for removing and installing drive pinion lock nut.
ST-499787500
5AT-25
General Description
ILLUSTRATION TOOL NUMBER 499575400 DESCRIPTION GAUGE REMARKS Used for measuring the total end play.
ST-499575400
18762AA000
COMPRESSOR SPECIAL TOOL
ST18762AA000
499755602
PRESS
Used for installing the parking gear.
ST-499755602
18680AA010
HOLDER GEAR
Used for removing reduction driven gear assembly. (2-piece set)
ST18680AA010
18766AA000
SUPPORT PULLER
Used for removing reduction driven gear assembly.
ST18766AA000
5AT-26
General Description
ILLUSTRATION TOOL NUMBER 18767AA000 DESCRIPTION REMOVER REMARKS Used to pull out the parking gear. Used to pull out the bearing from the VTD assembly.
ST18767AA000
2. GENERAL TOOL
TOOL NAME Depth gauge Thickness gauge Micrometer Spring scale Circuit tester TORX T70 Snap ring pliers REMARKS Used for measuring the transmission end play. Used for measuring clearance of the clutch, brake and oil pump. Used for measuring thickness of the drive pinion. Used for measuring the starting torque of the drive pinion. Used for measuring resistance and voltage. Used for removing and installing differential gear oil drain plug. Used for removing and installing each snap ring.
5AT-27

2. Automatic Transmission Fluid

A: INSPECTION
NOTE: The level of ATF varies with fluid temperature. Pay attention to the ATF temperature when checking ATF level. 1) Raise the ATF temperature by driving a distance of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 80C (158 176F) on Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> 2) Park the vehicle on a level surface. 3) After selecting all positions (P, R, N, D), set the select lever in P range. Idle the engine for 1 or 2 minutes, and measure the ATF level.
(B) (C)
F L F HOT
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the ATF drain plug to drain ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 3) Check the ATF condition. <Ref. to 5AT-29, CONDITION CHECK, Automatic Transmission Fluid.> 4) Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(B) (A)
(A)
(B)
COLD L
(C)
AT-03126 AT-04217
(A) Oil pan (B) ATF drain plug
4) Make sure that the ATF level is between upper and lower marks of the HOT side. 5) If the ATF level is below the lower mark, add recommended ATF until the fluid level is between upper and lower marks. CAUTION: Be careful not to exceed the upper level. When the transmission is cold, be careful not to add ATF to the upper level on HOT side. Overfilling of ATF may cause oil splashing. 6) Raise the ATF temperature by driving a distance of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 80C (158 176F) on Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> 7) Check the ATF for leaks. Visually check for leaks in the transmission. If there are leaks, replace the gasket, oil seal, plug or other parts.
5) Lower the vehicle. 6) Pour ATF from the oil charge pipe. Recommended fluid: <Ref. to 5AT-3, HYDRAULIC CONTROL AND LUBRICATION, SPECIFICATION, General Description.> CAUTION: Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble. Capacity: Fill with the same amount of ATF as drained. Capacity when transmission is overhauled: 9.6 10.0 2 (10.1 10.6 US qt, 8.4 8.8 Imp qt) 7) Check the level and leaks of ATF. <Ref. to 5AT28, INSPECTION, Automatic Transmission Fluid.>
5AT-28

C: CONDITION CHECK
NOTE: When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF.
Fluid condition Large amount of metallic pieces are found. Is thick and is a varnish-form fluid. Clouded fluid or bubbles are found in fluid. Trouble and possible cause Internal metal parts of transmission body are excessively worn. Clutch etc. is burned. Water is mixed. Corrective action Replace ATF and check if AT operates correctly. Replace ATF and check the AT body or vehicle for faulty. Replace ATF and check the water entering point.
5AT-29


A: INSPECTION
1) Park the vehicle on a level surface. 2) Remove the collector cover. 3) Remove the oil level gauge and wipe it clean. 4) Reinsert the level gauge all the way. Make sure the level gauge is inserted correctly and in the proper orientation. 5) Remove the oil level gauge again, and check the level of differential gear oil. If the differential gear oil level is below L line, add oil to bring the level up to F line. NOTE: To prevent overfilling the differential gear oil, do not add oil above the F line.
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the differential gear oil drain plug using TORX bit T70, and then drain differential gear oil. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. Be careful not to spill differential gear oil on the exhaust pipe to prevent it from emitting smoke or causing a fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely. 3) Tighten the differential gear oil drain plug using TORX bit T70. NOTE: Use a new gasket. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A) (B) (A) (B) AT-00017
(A) Upper level (B) Lower level

AT-03127
4) Lower the vehicle. 5) Pour gear oil into the gauge hole. Recommended gear oil: <Ref. to 5AT-3, RECOMMENDED GEAR OIL, SPECIFICATION, General Description.> Gear oil capacity: 1.3 1.5 2 (1.4 1.6 US qt, 1.1 1.3 Imp qt) 6) Check the level of differential gear oil. <Ref. to 5AT-30, INSPECTION, Differential Gear Oil.>
5AT-30
Road Test
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diagnose the condition of automatic transmission. NOTE: When performing the test, do not exceed posted speed limit.
2. D RANGE SHIFT FUNCTION

Check shifting between 1st mo 2nd mo 3rd mo 4th mo 5th while driving on normal city streets.
3. D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Check the shock level during kick-down at the same time.
5. ENGINE BRAKE OPERATION

Check the 4th gear engine brake by shifting down from 5th to 4th range while driving in 5th gear of manual mode [50 60 km/h (31 37 MPH)]. Check the 3rd gear engine brake by shifting down from 4th to 3rd range while driving in 4th gear of manual mode [50 60 km/h (31 37 MPH)]. Check the 2nd gear engine brake by shifting down from 3rd to 2nd range while driving in 3rd gear of manual mode [40 50 km/h (25 31 MPH)]. Check the 1st gear engine brake by shifting down from 2nd to 1st range while driving in 2nd gear of manual mode [20 30 km/h (12 19 MPH)].
6. LOCK-UP FUNCTION
When the accelerator is lightly depressed while driving on a flat road in lock-up range, check that rpm does not change abruptly.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more and shift to the P range. Check that the vehicle does not move when the parking brake is released.

Check for noise and vibration while driving and during shifting.
9. OIL LEAKAGE
After the driving test, inspect for oil leaks from the transmission body.
5AT-31
Stall Test
5. Stall Test
A: INSPECTION
NOTE: The stall test is extremely important in diagnosing the condition of an automatic transmission and engine. The test is necessary to measure the engine stall speeds in 2nd of manual mode. Purposes of the stall test: Operational check of the automatic transmission clutch Operational check of the torque converter clutch Engine performance check 1) Check that the throttle valve fully opens. 2) Check that the engine oil level is correct. 3) Check that the coolant level is correct. 4) Check that the ATF level is correct. 5) Check that the differential gear oil level is correct. 6) Raise the ATF temperature to 70 to 80C (158 to 176F) by driving a distance of 5 to 10 km (3 to 6 mile). Confirm the ATF temperature on Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> 7) Place the wheel chocks at the front and rear of all wheels and apply the parking brake. 8) Move the manual linkage to ensure it operates properly, then set to 2nd gear of manual mode. 9) While stepping hard on the brake pedal, gradually step on the accelerator pedal. 10) When the engine speed is stabilized, quickly record the engine speed and release accelerator pedal.
5AT-32
Stall Test
11) Shift the select lever to N range, and cool down the engine by idling it for one minute or more. NOTE: Do not perform a stall test for over 5 seconds at a time. (Perform with the throttle from fully closed to fully open to end up reading the stall speed.) Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. After performing the stall test, be sure to cool down the engine for at least one minute with the select lever set in P or N range, and at an idle speed of 1,200 rpm or less. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. Perform the stall test in S mode. When depressing the accelerator pedal again after performing the stall test for 5 seconds or more, the electronic throttle control remains closed for approx. 60 seconds. When the stall test is performed for 15 seconds or more continuously, the test is completed forcibly to protect the transmission unit. When depressing the accelerator pedal again, the electronic throttle control remains closed for approx. 60 seconds. Stall speed (at sea level): Turbo model 2,300 3,200 rpm Non-turbo model 1,900 2,200 rpm
Stall speed (at sea level) Over specified value Range 2nd gear of manual mode Possible faulty parts Line pressure too low Forward brake Direct clutch 3rd one-way clutch
5AT-33
Time Lag Test

6. Time Lag Test

A: INSPECTION
NOTE: When the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before shock is felt. Using this, check the condition of forward brake, reverse brake, 1st one-way clutch and 3rd one-way clutch. Perform the test at normal operation fluid temperature of 70 80C (158 176F). Be sure to allow one minute or more interval between tests. Make three measurements and take the average value. 1) Fully apply the parking brake. 2) Start the engine. Check the idle speed (A/C OFF). 3) Shift the select lever from N to D range. Using a stop watch, measure the time-lag from shifting the lever until the shock is felt. Time-lag Standard: 1.2 seconds or less If N o D time-lag is longer than specification: Line pressure too low Forward brake worn One-way clutch not operating properly 4) In the same manner, measure the time lag of N o R. Time-lag Standard: 1.5 seconds or less If N o R time lag is longer than specification: Line pressure too low Reverse brake worn
5AT-34
Line Pressure Test

7. Line Pressure Test

A: MEASUREMENT
NOTE: If the clutch or brake shows a sign of slippage, or shifting interval is not correct, check the line pressure. Excessive shock during up-shift may be due to the line pressure being too high. Slippage or inability to operate the vehicle may, in most cases, be due to loss of oil pressure for the operation of clutch, brake or control valve. 1) Set the vehicle on a lift. 2) Remove the under cover. 3) Remove the test plug and attach the ST. ST 498897200 OIL PRESSURE ADAPTER
AT-01752
4) Set the ST1 and ST2. ST1 498897200 OIL PRESSURE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY 5) Lower the vehicle, and pull ST2, which were set in step 4), into the vehicle. 6) Connect the Subaru Select Monitor to the data link connector and read the current data. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.>
5AT-35
Line Pressure Test

7) Perform the line pressure test. NOTE: Do not perform the line pressure test for 5 seconds or more at a time. Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. After performing the line pressure test, be sure to cool down the engine for at least one minute with the select lever set in P or N range and with the idle speed at 1,200 rpm or less. Fully open or fully close the throttle valve angle in order to match the P/L Solenoid Pressure displayed on the Subaru Select Monitor.
Range of the select lever Throttle valve angle Full closed Full open R Full closed 45 55C (113 131F) ATF temperature condition P/L Solenoid Pressure displayed on the Subaru Select Monitor kPa 500 700 2,150 2,150 Standard line pressure kPa (kg/cm2, psi) Target pressure 10 +190 (Target pressure 0.10 +1.94, Target pressure 1.45 +27.5) 1,320 1,520 (13.46 15.50, 191.4 220.4) 1,660 1,860 (16.93 18.97, 240.7 269.7)
8) Remove the ST and install the test plug. Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
5AT-36

8. Transfer Clutch Pressure Test

A: INSPECTION
1) Lift up the vehicle. 2) Remove the bolts holding the heat shield cover, and move the heat shield cover to the rear. 3) Remove the test plug and attach the ST. CAUTION: Be careful not to cut yourself on the heat shield cover when removing the test plugs and setting the ST. ST 498897800 OIL PRESSURE ADAPTER SET
AT-03275
4) Set the ST. ST 498575400
OIL PRESSURE GAUGE ASSY 5) Lower the vehicle, and pull ST, which were set in step 4), into the vehicle. 6) Connect the Subaru Select Monitor to the data link connector and read the current data. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.>
5AT-37

7) Perform the transfer clutch pressure test. NOTE: Do not perform the transfer clutch pressure test for 5 seconds or more at a time. Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. After performing the transfer clutch pressure test, be sure to cool down the engine for at least one minute with the select lever set in the P or N range, and at an idle speed of 1,200 rpm or less. Adjust the throttle valve angle in order to obtain the T/F Solenoid Pressure displayed on the Subaru Select Monitor.
Range of the select lever Throttle valve angle Full open Partial throttle Full closed 45 55C (113 131F) ATF temperature condition T/F Solenoid Pressure displayed on the Subaru Select Monitor kPa 1,200 500 0 Standard transfer clutch pressure kPa (kg/cm2, psi) 990 1,190 (10.09 12.13, 143.5 172.5) 400 600 (4.08 6.12, 58.0 87.0) 0 50 (0 0.51, 0 7.3)
8) Remove the ST and install the test plug. Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb) 9) Install the heat shield cover.
5AT-38

9. Automatic Transmission Assembly

A: REMOVAL
1) Set the vehicle on a lift. 2) Open the front hood and support with the hood stay. 3) Disconnect the ground cable from battery. 4) Remove the collector cover. 5) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 6) Remove the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 7) Remove the air breather hose. <Ref. to 5AT-65, REMOVAL, Air Breather Hose.> 8) Remove the starter. <Ref. to SC(H4SO)-6, REMOVAL, Starter.> 9) Disconnect the following connectors. Turbo model
(2) (1)
10) Remove the engine hanger. (Turbo model)
AT-04407
11) Disconnect the engine harness connectors, and then remove the engine hanger rear. (Non-turbo model)
(B)
(A) (A)
AT-02023
(A) Engine harness connectors (B) Engine hanger rear
12) Remove the water by-pass pipe. (Turbo model)

AT-04406
(1) Rear oxygen sensor connector (2) Transmission harness connectors
Non-turbo model
(2)
AT-01366
(1)
AT-04383
(1) Front oxygen (A/F) and rear oxygen sensor connector (2) Transmission harness connectors
5AT-39

13) Separate the torque converter from drive plate. CAUTION: Be careful not to drop bolts into converter housing. Be careful not to damage the mounting bolts. (1) Remove the service hole plug. (2) Remove the bolts which hold torque converter to drive plate. (3) Remove the four bolts by rotating the crank pulley a little at a time. (4) Make sure the torque converter moves freely by rotating with finger through the starter installation hole.
16) Remove the pitching stopper bracket.
AT-04234
17) Set the ST. Turbo model ST 41099AC000 ENGINE SUPPORT ASSY
ST
AT-01367
AT-02984
Non-turbo model ST1 41099AA010 ST2 41099AA020
ENGINE SUPPORT BRACKET ENGINE SUPPORT
ST AT-00103

AT-01370
AT-03873
18) Remove the air intake duct. (Turbo model) <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> 19) Remove the air cleaner case. (Turbo model) <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.> 20) Lift up the vehicle. (Turbo model) 21) Remove the under cover. (Turbo model) 22) Remove the center and rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.>
5AT-40

23) Remove the front exhaust pipe, rear exhaust pipe and muffler. (Non-turbo model) <Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 24) Remove the transmission mounting bolt (upper side).
28) Disconnect the connector from turbine speed sensor 1.
AT-01642
29) Remove the turbine speed sensor 1 connector mounting bolt and rotate the sensor by 180.
AT-03237
CAUTION: Failure to follow this procedure may cause the interference between vehicle body and sensor while removing/installing transmission, and resulting in damage.
AT-01331
26) Remove the ATF drain plug to drain ATF.

(B) (A)
AT-01640
30) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 31) Remove the shift select cable. <Ref. to CS-28, REMOVAL, Select Cable.> 32) Disconnect the hose from the ATF inlet and outlet pipes.
AT-03126
27) Remove the oil charge pipe.

AT-01390
33) Remove the front crossmember support plate. <Ref. to FS-14, REMOVAL, Front Crossmember Support Plate.>
AT-01371
5AT-41

34) Remove the two clutch housing cover securing bolts.
40) Remove the transmission mounting bolt and nut (lower side).
AT-01373
AT-03238
41) Remove the transmission. NOTE: Turn the engine support assembly from the vehicle under body to the left (to shorten the engine support length), and lower the rear of the engine for easy disassembly. Be careful not to allow breather pipe and etc. to touch the vehicle body when detaching the automatic transmission assembly by pulling it backward.
AT-01374
35) Remove the front stabilizer bracket. <Ref. to FS-15, REMOVAL, Front Stabilizer.> 36) Remove the bolts which secure front ball joint to the housing. <Ref. to FS-16, REMOVAL, Front Ball Joint.> 37) Pull out the drive shaft from transmission. 38) Set the transmission jack under the transmission.
AT-01376
39) Remove the rear crossmember.
AT-01377
5AT-42

B: INSTALLATION
1) Replace the front differential side retainer oil seal. (1) Remove the oil seal by using flat tip screwdriver etc. (2) Install a new oil seal using ST. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Apply oil to the oil seal lips. Be sure to replace the differential side oil seal after the procedure of removing front drive shaft from transmission.
4) Install the engine mounting bolt and nut (lower side). Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT-03238 ST
5) Install the transmission rear crossmember. Tightening torque: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
AT-00029
2) Attach the ST to converter case. ST 498277200 STOPPER SET

AT-01377
6) Remove the transmission jack. 7) Lower the vehicle. 8) Install the engine mounting bolt (upper side).
ST AT-00103
3) Install the transmission onto the engine. (1) Lift up the transmission gradually using transmission jack. (2) Engage at the spline.
AT-03237
9) Remove the ST from converter case. 10) Install the starter. <Ref. to SC(H4SO)-6, INSTALLATION, Starter.>
5AT-43

11) Install the torque converter to drive plate. CAUTION: Be careful not to drop bolts into converter housing. Be careful not to damage the mounting bolts. (1) Install the bolts which hold torque converter to drive plate. (2) Install all four bolts by rotating the crank pulley a little at a time. (3) Install the service hole. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 12) Remove the ST and install the pitching stopper bracket. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
15) Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR
ST AT-00110
16) Install the front drive shaft into the transmission. NOTE: Replace the circlip of drive shaft with a new part. 17) Install the front drive shaft into transmission, remove the ST and insert the drive shaft securely. 18) Install the inlet and outlet hoses to the ATF inlet and outlet pipes.
AT-04234
AT-01390
T1
19) Insert the ball joint into housing. <Ref. to FS-16, INSTALLATION, Front Ball Joint.> 20) Install the front stabilizer bracket. <Ref. to FS15, INSTALLATION, Front Stabilizer.>
T2
AT-03874
5AT-44

21) Install the clutch housing cover securing bolts.
26) Install the oil charge pipe. NOTE: Use new bolts. Tightening torque: 38 Nm (3.9 kgf-m, 28.0 ft-lb)
AT-01373
AT-01371
AT-01374
22) Install the front crossmember support plate. <Ref. to FS-14, INSTALLATION, Front Crossmember Support Plate.> 23) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 24) Install the shift select cable. <Ref. to CS-30, INSTALLATION, Select Cable.> 25) Install the turbine speed sensor 1 and harness, and then connect the connector. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb)
AT-01331
AT-01736
28) Install the center, rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 29) Install the front exhaust pipe, rear exhaust pipe and muffler. (Non-turbo model) <Ref. to EX(H6DO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, INSTALLATION, Muffler.> 30) Install the under cover. 31) Lower the vehicle. 32) Install the air cleaner case. (Turbo model) <Ref. to IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.> 33) Install the air intake duct. (Turbo model) <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.>
5AT-45

34) Connect the following connectors. Turbo model

(2) (1)
36) Install the engine hanger rear, and then connect the engine harness connector. (Non-turbo model)
(B)
(A) (A)
AT-04406 AT-02023
(1) Rear oxygen sensor connector (2) Transmission harness connectors
(A) Engine harness connectors (B) Engine hanger rear
Non-turbo model 37) Install the water by-pass pipe. (Turbo model)
(2)
(1)
AT-04383 AT-01366
(1) Front oxygen (A/F) and rear oxygen sensor connector (2) Transmission harness connectors
35) Install the engine hanger. (Turbo model)
AT-04407
38) Pour ATF from the oil charge pipe. <Ref. to 5AT-28, Automatic Transmission Fluid.> 39) Install the air breather hose. <Ref. to 5AT-65, INSTALLATION, Air Breather Hose.> 40) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 41) Install the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.> 42) Install the collector cover. 43) Connect the ground cable to battery. 44) Perform Clear Memory 2 operation. <Ref. to 5AT(diag)-20, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> 45) Execute the learning control promotion. <Ref. to 5AT(diag)-24, PROCEDURE, Learning Control.> 46) Perform the inspection at the end of repair work, and make sure there is no faulty as below; Excessive shift shock Oil leakage from the transmission body, etc. Occurrence of noise caused by interference etc.
5AT-46

10.Transmission Mounting System

A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from battery. 2) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 3) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 4) Remove the pitching stopper.
7) Remove the transmission rear crossmember.
AT-01377
8) Remove the rear cushion rubber from transmission.
AT-03873
2. TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER

1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the center and rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)14, REMOVAL, Muffler.> 4) Remove the front exhaust pipe, rear exhaust pipe and muffler. (Non-turbo model) <Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 5) Remove the heat shield cover.
AT-01331
6) Set the transmission jack under transmission. Make sure that the support plate of transmission jack does not touch the oil pan.
5AT-47

B: INSTALLATION
1. PITCHING STOPPER
T1
AT-01331
T2
AT-03874
2) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 3) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.> 4) Connect the ground cable to battery.
5) Install the center, rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 6) Install the front exhaust pipe, rear exhaust pipe and muffler. (Non-turbo model) <Ref. to EX(H6DO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, INSTALLATION, Muffler.> 7) Connect the ground cable to battery.

1) Install the rear cushion rubber to the transmission. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb) 2) Install the crossmember. Tightening torque: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
C: INSPECTION
Repair or replace parts if the results of the inspection below are not satisfied.
1. PITCHING STOPPER
Check pitching stopper for bends or damage. Check that there are no cracks, hardening or damage on rubber parts.

Check crossmember for bends or damage. Check that there are no cracks, hardening, or damage on cushion rubbers.
AT-01377
3) Remove the transmission jack.
5AT-48
Extension Case Oil Seal

11.Extension Case Oil Seal

A: INSPECTION
Inspect there is no ATF leakage from the joint of transmission and propeller shaft. If a leak is found, replace the oil seal. <Ref. to 5AT-49, REPLACEMENT, Extension Case Oil Seal.>
B: REPLACEMENT
1) Lift up the vehicle. 2) Clean the transmission exterior. 3) Remove the ATF drain plug to drain ATF. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the ATF will be hot. Be careful not to burn yourself. 4) Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(B) (A)
8) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 9) Using the ST, remove the oil seal. ST 398527700 PULLER ASSY 10) Using the ST, install the oil seal. ST 498057300 INSTALLER 11) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 12) Install the heat shield cover.
AT-01331
AT-03126
13) Install the rear exhaust pipe and muffler. (Turbo model) <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)14, INSTALLATION, Muffler.> 14) Install the rear exhaust pipe and muffler. (Nonturbo model) <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, INSTALLATION, Muffler.> 15) Pour ATF from the oil charge pipe. <Ref. to 5AT-28, Automatic Transmission Fluid.> 16) Check the level and leaks of the ATF. <Ref. to 5AT-28, INSPECTION, Automatic Transmission Fluid.>
5) Remove the rear exhaust pipe and muffler. (Turbo model) <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 6) Remove the rear exhaust pipe and muffler. (Non-turbo model) <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 7) Remove the heat shield cover.
AT-01331
5AT-49

12.Differential Side Retainer Oil Seal

A: INSPECTION
Check for leakage of gear oil from differential side retainer oil seal part. If there is an oil leak, replace the oil seal.
8) Using the ST, install the differential side retainer oil seal by lightly tapping with a hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
ST
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the front exhaust pipe and center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)5, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 3) Remove the front exhaust pipe. (Non-turbo model) <Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust Pipe.> 4) Remove the differential gear oil drain plug using TORX bit T70, and then drain differential gear oil. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely.
(A) (B)
AT-00029
9) Apply oil to the oil seal lips. 10) Install the front drive shaft. <Ref. to DS-22, INSTALLATION, Front Drive Shaft.> 11) Install the front exhaust pipe and the center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)6, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> 12) Install the front exhaust pipe. (Non-turbo model) <Ref. to EX(H6DO)-5, INSTALLATION, Front Exhaust Pipe.> 13) Lower the vehicle. 14) Pour gear oil through the level gauge hole. <Ref. to 5AT-30, Differential Gear Oil.> 15) Check the level of differential gear oil. <Ref. to 5AT-30, INSPECTION, Differential Gear Oil.>
AT-01362
5) Tighten the differential gear oil drain plug. NOTE: Use a new gasket. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb) 6) Separate the front drive shaft from the transmission. <Ref. to DS-22, REMOVAL, Front Drive Shaft.> 7) Remove the differential side retainer oil seal using driver wrapped with vinyl tape etc.
5AT-50
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
Inhibitor switch cannot be checked, because the inhibitor switch is installed on control valve assembly. When a malfunction occurs, refer to 5AT (diag) section. <Ref. to 5AT(diag)-35, DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
5AT-51

14.Front Vehicle Speed Sensor

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Disconnect the rear vehicle speed sensor connector. NOTE: Secure the harness of the transmission harness to the transmission body using wire etc.
8) Remove the front vehicle speed sensor securing bolt.
AT-03227
9) Remove the front vehicle speed sensor through the hole of AT transmission main case.
AT-04218
3) Remove the extension case.
AT-03226
4) Remove the center differential carrier. <Ref. to 5AT-77, REMOVAL, Center Differential Carrier.> 5) Lay along the transmission case, and then remove the oil pan. 6) Remove the old gasket on the oil pan and transmission case completely. 7) Disconnect the front vehicle speed sensor connector.
AT-04219
5AT-52

B: INSTALLATION
1) Install the front vehicle speed sensor. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb)
6) Install the extension case. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-03226
AT-03227
2) Connect the front vehicle speed sensor connector.
7) Connect the rear vehicle speed sensor connector.
AT-04218
AT-04219
8) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.> 9) Pour ATF from the oil charge pipe. <Ref. to 5AT28, Automatic Transmission Fluid.> 10) Check the level and leaks of ATF. <Ref. to 5AT28, INSPECTION, Automatic Transmission Fluid.>
AT-03249
4) Install the oil pan by equally tightening the bolts. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 5) Install the center differential carrier. <Ref. to 5AT-77, INSTALLATION, Center Differential Carrier.>
5AT-53

15.Rear Vehicle Speed Sensor

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Clean the transmission exterior. 5) Drain the ATF completely. <Ref. to 5AT-28, REPLACEMENT, Automatic Transmission Fluid.> 6) Remove the center and rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)7, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 7) Remove the rear exhaust pipe and muffler. (Non-turbo model) <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 8) Remove the heat shield cover.
13) Disconnect the rear vehicle speed sensor connector.
AT-04218
AT-04261
AT-01331
9) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 10) Place the transmission jack under the transmission. NOTE: Make sure that the support plate of transmission jack does not touch the cross. 11) Remove the transmission rear crossmember bolt.
AT-01377
12) Lower the transmission jack. NOTE: Do not separate the transmission jack and transmission.
5AT-54

B: INSTALLATION
8) Lower the vehicle. 9) Pour ATF from the oil charge pipe. <Ref. to 5AT28, Automatic Transmission Fluid.> 10) Check the level and leaks of ATF. <Ref. to 5AT28, INSPECTION, Automatic Transmission Fluid.>
AT-04261
AT-04218
3) Install the transmission rear crossmember bolt. Tightening torque: 75 Nm (7.6 kgf-m, 55.3 ft-lb) 4) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 5) Install the heat shield cover.
AT-01331
6) Install the center, rear exhaust pipes and the muffler. (Turbo model) <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 7) Install the rear exhaust pipe and muffler. (Nonturbo model) <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, INSTALLATION, Muffler.>
5AT-55
Turbine Speed Sensor 1

16.Turbine Speed Sensor 1

A: REMOVAL
1) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 2) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 3) Lift up the vehicle. 4) Disconnect the turbine speed sensor 1 connector.
AT-01387
5) Remove the turbine speed sensor 1.
B: INSTALLATION
1) Install the turbine speed sensor 1. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb) 2) Connect the turbine speed sensor 1 connector.
AT-01387
3) Lower the vehicle. 4) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 5) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
5AT-56
Control Valve Body

17.Control Valve Body

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Clean the transmission exterior. 5) Remove the ATF drain plug to drain ATF. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the ATF will be hot. Be careful not to burn yourself. 6) Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 20 Nm (2.0 kgf-m, 14.8 ft-lb) 7) Remove the oil pan. CAUTION: Be sure to prevent the entering of dust and other foreign matters into oil pan. 8) Remove the magnet.
12) Remove the control valve body. NOTE: The control valve body is replaced as an assembly only, because it is a non-disassembly part.
AT-04221
AT-01959
9) Clean the magnet. 10) Completely remove the remaining liquid gasket on the transmission case and oil pan. 11) Disconnect the control valve connector and front vehicle speed sensor connector.
(A)
(A)
(B)
AT-04220
(A) Control valve connector (B) Front vehicle speed sensor connector
5AT-57
Control Valve Body

B: INSTALLATION
1) Check the control valve body for dust and other foreign matter. 2) Install the control valve body to transmission by equally tightening the bolts. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
(1) (1) (1) (1) (2) (2) (1) (1) (1) (1) (1) (1)
5) Apply liquid gasket to the oil pan. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
AT-01955 (1)
6) Install the oil pan by equally tightening the bolts. Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb) 7) Pour ATF through the oil charge pipe. <Ref. to 5AT-28, Automatic Transmission Fluid.> 8) Check the ATF level. <Ref. to 5AT-28, INSPECTION, Automatic Transmission Fluid.> 9) Perform Clear Memory 2 operation. <Ref. to 5AT(diag)-20, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> 10) Execute the learning control promotion. <Ref. to 5AT(diag)-24, PROCEDURE, Learning Control.> 11) Perform the inspection at the end of repair work, and make sure there is no faulty as below; Excessive shift shock Oil leakage from the transmission body, etc. Occurrence of noise caused by interference etc.
AT-04222
(1) 30 mm (1.18 in) (2) 40 mm (1.57 in)
3) Connect the control valve connector.

(A)
(A)
(B)
AT-04220
(A) Control valve connector (B) Front vehicle speed sensor connector
C: INSPECTION
Check each parts for holes, damages or other foreign matters.
AT-01959
5AT-58
ATF Filter
18.ATF Filter
A: REMOVAL
NOTE: The ATF filter is maintenance free. 1) Disconnect the battery ground cable and remove the battery from the vehicle.
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of new ATF filter. 2) Install the ATF filter. Turn it by hand, being careful not to damage oil seal. 3) Tighten the ATF filter using ST. Calculate the ATF filter tightening torque using following formula. T2 = L2/(L1 + L2) T1 T1: 14 Nm (1.4 kgf-m, 10.3 ft-lb) [Required torque setting] T2: Tightening torque L1: ST length 78 mm (3.07 in) L2: Torque wrench length Example:
Torque wrench length mm (in) 100 (3.94) 150 (5.91) 200 (7.87) Tightening torque Nm (kgf-m, ft-lb) 7.7 (0.8, 5.7) 9.0 (0.9, 6.6) 10 (1.0, 7.4)
IN-00203
2) Remove the harness securing bracket.
NOTE: Align the ST with the torque wrench while tightening the ATF filter. ST 498545400 OIL FILTER WRENCH 4) Fill ATF. <Ref. to 5AT-28, Automatic Transmission Fluid.> 5) Inspect the level of ATF. <Ref. to 5AT-28, INSPECTION, Automatic Transmission Fluid.> 6) Install the harness securing bracket. 7) Install the battery.
C: INSPECTION
Check for rust, hole, ATF leaks or other damage. Replace the part if any damage is found in the inspection.
AT-01381
3) Using the ST, remove the ATF filter. ST 498545400 OIL FILTER WRENCH
5AT-59
Transmission Control Module (TCM)

19.Transmission Control Module (TCM)

A: REMOVAL
1) Disconnect the ground cable from battery. 2) Remove the lower cover and then disconnect the connector. 3) Disconnect the connector from TCM.
(A)
(B)
AT-04384
(A) Transmission control module (TCM) (B) Steering column
4) Remove the TCM.
B: INSTALLATION
1) Install the TCM. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
(A)
(B)
AT-04384
(A) Transmission control module (TCM) (B) Steering column
2) Connect the connector to the TCM. 3) Install in the reverse order of removal. 4) Perform Clear Memory 2 operation. <Ref. to 5AT(diag)-20, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> 5) Execute the learning control promotion. <Ref. to 5AT(diag)-24, PROCEDURE, Learning Control.> 6) Perform the inspection at the end of repair work, and make sure there is no faulty as below; Excessive shift shock Oil leakage from the transmission body, etc. Occurrence of noise caused by interference etc.
5AT-60
Lateral G Sensor
20.Lateral G Sensor
A: NOTE
For removal and installation, refer to Vehicle Dynamics Control (VDC) system. <Ref. to VDC-16, Yaw Rate and Lateral G Sensor.>
5AT-61

21.ATF Cooler Pipe and Hose

A: REMOVAL
1) Set the vehicle on a lift. 2) Remove the battery. 3) Lift up the vehicle. 4) Remove the under cover. 5) Remove the heat shield cover.
8) Disconnect the ATF cooler pipe from frame.
CO-02355
6) Disconnect the ATF cooler hose from the radiator. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
AT-01347
9) Remove the ATF inlet pipe and outlet pipe. NOTE: When disconnecting the outlet pipe, be careful not to lose the ball and spring used together with retaining screw.
AT-01345
(A) (B) AT-01383
7) Disconnect the ATF cooler hoses from the pipes. NOTE: Do not use a screwdriver or other pointed tools. If it is hard to remove the hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.
(A) ATF outlet pipe (B) ATF inlet pipe
AT-04451
5AT-62

B: INSTALLATION
1) Install the ATF inlet pipe and outlet pipe with new washers. NOTE: Use new bolts for the contact area of the converter case. Tightening torque: T1: 40 Nm (4.1 kgf-m, 29.5 ft-lb) T2: 38 Nm (3.9 kgf-m, 28.0 ft-lb) T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
3) Connect the ATF cooler hose to the pipe on the transmission side. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
T2
AT-04451
4) Connect the ATF cooler hose to the pipe on the radiator side.
T2 T3 T1 AT-03133
2) Install the ATF cooler pipe to frame.
NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
AT-01345
5) Install the heat shield cover. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb)
AT-01347
CO-02355
6) Install the under cover. 7) Install the battery. 8) Fill ATF. <Ref. to 5AT-28, Automatic Transmission Fluid.> NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.
5AT-63

C: INSPECTION
Repair or replace any faulty hoses, pipes, clamps, and washers found in the inspection below. 1) Check for ATF leaks in joints between the transmission, radiator, pipes, and hoses. 2) Check the clamp for deformation. 3) Lightly bend the hose and check for cracks in the surface or other damages. 4) Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was installed by pressing with your fingernail. 5) Check for peeling, cracks, and deformation at the tip of the hose.
5AT-64
Air Breather Hose

22.Air Breather Hose

A: REMOVAL
1) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 2) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 3) Disconnect the air breather hose.
AT-03252
B: INSTALLATION
1) Connect the air breather hose.
AT-03252
2) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 3) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
C: INSPECTION
5AT-65
Oil Charge Pipe

23.Oil Charge Pipe

A: REMOVAL
1) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 2) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.> 3) Remove the oil charge pipe, and then remove the O-ring from flange side.
(A)
(B)
AT-01386
B: INSTALLATION
1) Install the oil charge pipe with a new O-ring. NOTE: Use new bolts. Tightening torque: 38 Nm (3.9 kgf-m, 28.0 ft-lb)
(A)
(B)
AT-01386
2) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 3) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
C: INSPECTION
Make sure the oil charge pipe is not deformed or damaged.
5AT-66
Torque Converter Assembly

24.Torque Converter Assembly

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter and oil pump shaft horizontally. NOTE: Be sure not to scratch the inside of bushing in oil pump shaft. Be careful that the oil pump shaft may drawn out simultaneously.
B: INSTALLATION
1) When the oil pump shaft is removed, install the shaft to torque converter. NOTE: Make sure the clip is firmly inserted. 2) Install the oil pump shaft to torque converter, and then make sure that the clip is secured on groove. 3) Apply ATF to the revolving and sliding surface of the oil pump shaft. 4) Holding the torque converter assembly by hand, lightly rotate it to engage with the oil pump rotor. 5) Check the protruding dimension of the torque converter assembly. Dimension A: 8 mm (0.31 in) or less
A
AT-00113
3) Remove the oil pump shaft from torque converter as necessary.

A Measured value
AT-04911
C: INSPECTION
Make sure the ring gear and protrusion of torque converter end are not deformed or damaged.
5AT-67
Extension Case
25.Extension Case
A: REMOVAL
1) Remove the transmission assembly. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Disconnect the rear vehicle speed sensor connector.
B: INSTALLATION
1) Attach the selected reduction driven gear shim to end surface of reduction driven gear with vaseline. <Ref. to 5AT-76, ADJUSTMENT, Reduction Driven Gear.> 2) Install the extension case. NOTE: Use a new gasket. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-04218

AT-03226
AT-04261
4) Remove the extension case.
AT-04261
AT-03226
AT-04218
5) Install the transmission assembly. <Ref. to 5AT43, INSTALLATION, Automatic Transmission Assembly.>
5AT-68
Extension Case
C: DISASSEMBLY
1) Take out the transfer clutch and multi-plate clutch hub assembly by lightly tapping the end of rear drive shaft. NOTE: Be careful not to damage the oil seal of the extension. 2) Remove the snap ring using the ST and press. ST 18762AA000 COMPRESSOR SPECIAL TOOL
ST
D: ASSEMBLY
1) Press-fit the new oil seal using ST and the press. ST 498057300 INSTALLER 2) Press-fit the dust cover. 3) Insert the transfer clutch assembly, spring retainer, return spring and clutch spring retainer.
(D) (C) (B) (A)
AT-03230
AT-03228
3) Remove the clutch piston by applying compressed air.
(A) (B) (C) (D)
Clutch spring retainer Return spring Spring retainer Transfer clutch piston ASSY
4) Using the ST and compressor, install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL
ST
AT-03229
4) Remove the dust cover from extension case. 5) Remove the oil seal from the extension case.
AT-03228
5) Install the transfer clutch. <Ref. to 5AT-70, INSTALLATION, Transfer Clutch.> 6) Install the multi-plate hub assembly.
E: INSPECTION
Use compressed air to make sure the extension case routes are not clogged or leaking. Inspect the extension end play, and adjust it to within the standard value. <Ref. to 5AT-70, ADJUSTMENT, Transfer Clutch.>
5AT-69
Transfer Clutch
26.Transfer Clutch
A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Remove the extension case, and then remove the transfer clutch. <Ref. to 5AT-68, REMOVAL, Extension Case.> <Ref. to 5AT-69, DISASSEMBLY, Extension Case.>
D: ADJUSTMENT
1. REAR DRIVE SHAFT SHIM SELECTION
1) Insert the rear drive shaft into the reduction drive gear and center differential assembly.
B: INSTALLATION
1) Select the rear drive shaft shim. <Ref. to 5AT-70, ADJUSTMENT, Transfer Clutch.> 2) Select driven plate No. 3 <Ref. to 5AT-70, ADJUSTMENT, Transfer Clutch.> 3) Install the extension case. <Ref. to 5AT-68, INSTALLATION, Extension Case.> 4) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
AT-03231
2) Using the ST, measure the depth A, which is from mating surface of extension case to ball bearing outer ring contact surface. ST 398643600 GAUGE
C: INSPECTION
Inspect the drive plate facing for wear and damage. Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation. Check that the D-ring is not damaged. Inspect the extension end play, and adjust it to within the standard value. <Ref. to 5AT-70, ADJUSTMENT, Transfer Clutch.>
A
AT-03232
A Measured value
3) Using the ST, measure the height B from the AT main case mating surface to ball bearing outer ring contact surface. ST 398643600 GAUGE
AT-03233
B Measured value
5AT-70
Transfer Clutch
4) Calculation formula: When clearances are 0.05 mm (0.0020 in): T (mm) = A B + 0.23 [T (in) = A B + 0.0091] When clearances are 0.25 mm (0.0098 in): T (mm) = A B + 0.03 [T (in) = A B + 0.0012] A: Depth from end of extension case to ball bearing outer ring contact surface B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface T: Shim thickness Standard: 0.05 0.25 mm (0.0020 0.0098 in) NOTE: Calculation formula for T above is applied when measuring with the ST (398643600 GAUGE). When not using the ST, When clearances are 0.05 mm (0.0020 in): T (mm) = (A D) ((B E) 0.28) 0.05 [T (in) = (A D) ((B E) 0.0110) 0.0020] When clearances are 0.25 mm (0.0098 in): T (mm) = (A D) ((B E) 0.28) 0.25 [T (in) = (A D) ((B E) 0.0110) 0.0098] is applied. T: Shim thickness A: Depth from end of extension case to ball bearing outer ring contact surface B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface D: Thickness of collar used when measuring A E: Thickness of collar used when measuring B 0.28 (0.0110): Gasket thickness (Unit mm (in))
Adjustment shim Part No. Thickness mm (in) 33281AA040 0.2 (0.008) 33281AA050 0.5 (0.020) 33281AA060 0.3 (0.012)
2. SELECTION OF DRIVEN PLATE NO. 3

1) Install the drive plate and driven plate to the center differential carrier. 2) Measure the depth A from the mating surface of the extension case to the multi-plate clutch (LSD) piston.
AT-03234
A Measured value
3) Using the ST, measure the height B from the AT main case mating surface to end of ST, and then subtract the thickness of ST (piston guide) (50 mm (1.97 in)) from measured value. ST 398744300 PISTON GUIDE
AT-03235
B Measured value
5AT-71
Transfer Clutch
4) Calculation formula: When clearances are 0.2 mm (0.008 in): T (mm) = A B + 0.08 [T (in) = A B + 0.0031] When clearances are 0.6 mm (0.024 in): T (mm) = A B 0.32 [T (in) = A B 0.0126] T: Thickness of driven plate No. 3 A: Depth from mating surface of extension case to multi-plate clutch (LSD) piston B: Height from AT main case mating surface to end of ST Standard: 0.2 0.6 mm (0.008 0.024 in) NOTE: Calculation formula for T is applied when measuring using ST (398643600 GAUGE, 398744300 PISTON GUIDE). When not using the ST, When clearances are 0.2 mm (0.008 in): T (mm) = A (B D 0.28) 0.2 [T (in) = A (B D 0.011) 0.008] When clearances are 0.6 mm (0.024 in): T (mm) = A (B D 0.28) 0.6 [T (in) = A (B D 0.011) 0.024] is applied. T: Thickness of driven plate No. 3 A: Depth from mating surface of extension case to multi-plate clutch (LSD) piston B: Height from the AT main case mating surface to the contact face of the tool that was used as the substitute of the ST. D: Thickness of tool used when measuring B 0.28 (0.011): Gasket thickness (Unit mm (in)) If it is out of specification, select the driven plate No. 3 to adjust within the specification.
Driven plate No. 3 Part No. Thickness mm (in) 31589AA041 1.6 (0.063) 31589AA050 2.0 (0.079) 31589AA060 2.4 (0.094) 31589AA070 2.8 (0.110)
5AT-72
Rear Drive Shaft

27.Rear Drive Shaft

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor, and then remove the extension case. <Ref. to 5AT-68, REMOVAL, Extension Case.> 3) Pull out the rear driveshaft from center differential assembly.
2) Using a press, remove the front and rear side ball bearings and clutch hub.
(B) (A) (C)
AT-00151
(A) Rear ball bearing (B) Rear drive shaft (C) Clutch hub
D: ASSEMBLY
AT-03231
4) Remove the drive plate and driven plate.
B: INSTALLATION
1) Select shims. <Ref. to 5AT-70, ADJUSTMENT, Transfer Clutch.> 2) Install the drive plate and driven plate. 3) Insert the rear driveshaft into the center differential assembly. 4) Combine the extension case, and then install the rear vehicle speed sensor. <Ref. to 5AT-68, INSTALLATION, Extension Case.> 5) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
NOTE: Use new ball bearings and revolution gear. Make sure the clutch hub is facing the correct direction.
(B)
(A)
(C)
(D) AT-00152
C: DISASSEMBLY
1) Using a press, remove the revolution gear.
(A)
(A) (B) (C) (D)
Front side Clutch hub Rear side Revolution gear
E: INSPECTION
Check each parts for holes, damages or other foreign matters. Inspect the extension end play, and adjust it to within the standard value. <Ref. to 5AT-70, ADJUSTMENT, Transfer Clutch.>
AT-00149
(A) Revolution gear
5AT-73


A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor, and separate the extension case from transmission case. <Ref. to 5AT-68, REMOVAL, Extension Case.> 3) Remove the center differential carrier. <Ref. to 5AT-77, REMOVAL, Center Differential Carrier.> 4) Set the range select lever to the P range. 5) Using ST1, ST2 and ST3, pull out the reduction driven gear. ST1 499737100 PULLER SET ST2 18680AA010 GEAR HOLDER ST3 18766AA000 SUPPORT PULLER
ST2
C: DISASSEMBLY
1) Remove the ball bearing from reduction driven gear using ST. ST 498077300 REMOVER
(A) ST
AT-00157
(A) Ball bearing
2) Remove the ball bearing on the reverse side with the same procedure as step 1). ST 498077300 REMOVER
(A) ST
(A) ST3 ST1 ST2 AT-03271
(A) Reduction driven gear
B: INSTALLATION
1) Set the range select lever to the P range. 2) Use a plastic hammer to install reduction driven gear assembly. 3) Select the reduction gear shims. <Ref. to 5AT76, ADJUSTMENT, Reduction Driven Gear.> 4) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. <Ref. to 5AT-68, INSTALLATION, Extension Case.> 5) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
(A) Ball bearing
AT-01969
3) Remove the snap ring of the parking gear.
AT-03264
5AT-74

4) Using the ST, remove the parking gear. ST 18767AA000 REMOVER
D: ASSEMBLY
1) Using the ST, install the parking gear. ST 499755602 PRESS
ST
ST
AT-03265
AT-03266
2) Install the snap ring.
AT-03264
3) Install the new ball bearing to reduction driven gear using press. ST 18654AA000 INSTALLER
ST
AT-03267
4) Install the ball bearing on the reverse side with the same procedure as step 3). ST 18654AA000 INSTALLER
ST
AT-03268
5AT-75

E: INSPECTION
Make sure the ball bearing and gear is not deformed or damaged.
F: ADJUSTMENT
1) Using the ST, measure the height A from the AT main case mating surface to ball bearing outer ring contact surface. ST 499575400 GAUGE
ST
3) Calculation formula: Select the ball bearing shim from the table to adjust clearances within 0.05 0.25 mm (0.0020 0.0098 in). When clearances are 0.05 mm (0.0020 in): T (mm) = B A + 0.23 [T (in) = B A + 0.0091] When clearances are 0.25 mm (0.0098 in): T (mm) = B A + 0.03 [T (in) = B A + 0.0012] T: Shim clearance A: Height from the mating surface of the AT main case to the ball bearing outer ring end surface B: Depth from mating surface of extension case to ball bearing outer ring contact surface
Reduction gear shim Part No. Thickness mm (in) 31288AA030 0.2 (0.008) 31288AA050 0.5 (0.020) 31288AA060 0.3 (0.012)
AT-03269
A Measured value
2) Using the ST, measure the depth B, which is from mating surface of extension case to ball bearing outer ring contact surface. ST 499575400 GAUGE
B ST
AT-03270
B Measured value
5AT-76
Center Differential Carrier

29.Center Differential Carrier

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor, and separate the extension case from transmission case. <Ref. to 5AT-68, REMOVAL, Extension Case.> 3) Extract the rear drive shaft. <Ref. to 5AT-73, REMOVAL, Rear Drive Shaft.> 4) Pull out the center differential carrier assembly.
C: DISASSEMBLY
(A)
AT-02015
(A) Seal ring
2) Using a press and ST, remove the ball bearing. ST 498077600 REMOVER
AT-01972
5) Pull out the shim(s) from transmission case.
B: INSTALLATION
1) Install the center differential assembly with the shim(s). NOTE: Press-fit it to the bottom of bearing shoulder completely.
AT-00167
3) Remove the snap ring, and pull out the shaft from center differential assembly.
(B) (A)
AT-01973 AT-01972
2) Insert the rear drive shaft. <Ref. to 5AT-73, INSTALLATION, Rear Drive Shaft.> 3) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. <Ref. to 5AT-68, INSTALLATION, Extension Case.> 4) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
(A) Snap ring (B) Shaft
5AT-77

4) Remove the thrust washers, pinion gears and washers from center differential assembly.
(A)
AT-00169
(A) Pinion gear
5) Pull out the intermediate shaft and thrust bearing.
D: ASSEMBLY
1) Install the thrust washer onto intermediate shaft. 2) Install the thrust bearing onto intermediate shaft. 3) Install the pinion gears and washers. 4) Insert the shaft into the center differential assembly. 5) Install the snap ring. 6) Using a press, install a new ball bearing into the center differential assembly. ST 498077000 REMOVER
(A) ST (B)
AT-00170
(A) Plate (B) Center differential carrier
7) Apply vaseline onto the seal ring outer surface and shaft grooves. 8) Install a new seal ring.
E: INSPECTION
Check each parts for holes, damages or other foreign matters. Inspect the extension end play, and adjust it to within the standard value. <Ref. to 5AT-70, ADJUSTMENT, Transfer Clutch.>
5AT-78
Parking Pawl
30.Parking Pawl
A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Remove the extension case. <Ref. to 5AT-68, REMOVAL, Extension Case.> 3) Remove the center differential carrier. <Ref. to 5AT-77, REMOVAL, Center Differential Carrier.> 4) Remove the front vehicle speed sensor. <Ref. to 5AT-52, REMOVAL, Front Vehicle Speed Sensor.> 5) Remove the parking support actuator.
B: INSTALLATION
1) Set the transmission to the N range. 2) Install the parking pawl, parking pawl shaft and return spring.
AT-03272
3) Install the parking support actuator. Tightening torque: 10r2 Nm (1.0r0.2 kgf-m, 7.4r1.5 ft-lb)
AT-03236
6) Remove the parking pawl, parking pawl shaft and return spring.
AT-03236
AT-03272
5AT-79
Parking Pawl
4) Using the ST, tighten the bolts which tightened in step 3) with specified angle. Tightening angle: 17r2 ST 18854AA000 ANGLE GAUGE NOTE: Do not use extension as much as possible.
6) Install the front vehicle speed sensor. <Ref. to 5AT-53, INSTALLATION, Front Vehicle Speed Sensor.> 7) Install the center differential carrier. <Ref. to 5AT-77, INSTALLATION, Center Differential Carrier.> 8) Install the extension case. <Ref. to 5AT-68, INSTALLATION, Extension Case.> 9) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
C: INSPECTION
Make sure that the tab of parking pawl on reduction driven gear is not worn or otherwise damaged.
ST AT-02071 ST
AT-02072
5) Make sure that the return spring is sticking out of the parking pole hole.
B B
(A)
(B)
AT-03370
(A) Parking pawl (B) Return spring
5AT-80
Converter Case
31.Converter Case
A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Remove the torque converter assembly. <Ref. to 5AT-67, REMOVAL, Torque Converter Assembly.> 3) Remove the transmission harness connector from stay. 4) Remove the turbine speed sensor 1. <Ref. to 5AT-56, REMOVAL, Turbine Speed Sensor 1.> 5) Remove the oil charge pipe. <Ref. to 5AT-66, REMOVAL, Oil Charge Pipe.> 6) Remove the ATF inlet and outlet pipes. <Ref. to 5AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 7) Remove the converter case attachment bolts. 8) Lay along the transmission body, and then remove the oil pan. 9) Remove the three converter case mounting bolts (TORX). ST 18676AA020 TORX WRENCH
B: INSTALLATION
1) Check the appearance of each component and clean them. 2) Press-fit the oil seal to converter case using ST. ST 499587100 OIL SEAL INSTALLER
ST
AT-01979
3) Install the front differential assembly to the case. <Ref. to 5AT-92, INSTALLATION, Front Differential Assembly.> 4) Install the right and left side retainers. <Ref. to 5AT-96, ADJUSTMENT, Front Differential Assembly.> 5) Apply proper amount of liquid gasket to the entire matching surface of converter case. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
AT-04224
10) Separate the converter case by lightly tapping with plastic hammer. 11) Remove the front differential assembly. <Ref. to 5AT-92, REMOVAL, Front Differential Assembly.> 12) Remove the oil seal from converter case.
AT-01975
6) Install the converter case assembly without damaging bushing and oil seal. NOTE: Use new bolts for the oil charge pipe and ATF cooler pipe. Tightening torque: Oil charge pipe and ATF cooler pipe 38 Nm (3.9 kgf-m, 28.0 ft-lb) Other than above 41 Nm (4.2 kgf-m, 30.2 ft-lb)
5AT-81
Converter Case
7) Install the three converter case mounting bolts (TORX). ST 18676AA020 TORX WRENCH Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
AT-04224
8) Apply proper amount of liquid gasket to the entire oil pan mating surface, and then install it. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent Tightening torque: 5 Nm (0.5 kgf-m, 3.7 ft-lb)
AT-03249
9) Install the transmission harness connector to the stay. 10) Install the air breather hose. <Ref. to 5AT-65, INSTALLATION, Air Breather Hose.> 11) Install the ATF cooler pipe. <Ref. to 5AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 12) Install the oil charge pipe with O-ring. <Ref. to 5AT-66, INSTALLATION, Oil Charge Pipe.> 13) Install the torque converter assembly. <Ref. to 5AT-67, INSTALLATION, Torque Converter Assembly.> 14) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
C: INSPECTION
Measure the backlash, and then adjust it to be within standard values. <Ref. to 5AT-90, ADJUSTMENT, Drive Pinion Shaft Assembly.>
5AT-82
Oil Pump Cover

32.Oil Pump Cover

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter assembly. <Ref. to 5AT-67, REMOVAL, Torque Converter Assembly.> 3) Remove the transmission harness connector from stay. 4) Remove the oil charge pipe. <Ref. to 5AT-66, REMOVAL, Oil Charge Pipe.> 5) Remove the ATF inlet and outlet pipes. <Ref. to 5AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 6) Separate the converter case and transmission case. <Ref. to 5AT-81, REMOVAL, Converter Case.> 7) Remove the oil pump cover mounting bolt, and then separate the oil pump cover from the AT main case by lightly tapping with plastic hammer.
B: INSTALLATION
1) Secure the oil pump cover. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
AT-01976
AT-01976
2) Install the converter case assembly to the transmission case assembly. <Ref. to 5AT-81, INSTALLATION, Converter Case.> 3) Install the transmission harness connector to the stay. 4) Install the ATF cooler pipe. <Ref. to 5AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 5) Install the oil charge pipe together with an Oring. <Ref. to 5AT-66, INSTALLATION, Oil Charge Pipe.> 6) Install the torque converter assembly. <Ref. to 5AT-67, INSTALLATION, Torque Converter Assembly.> 7) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
5AT-83
Oil Pump Cover

C: DISASSEMBLY
1. FRONT BRAKE
2. OIL PUMP
1) Take out the oil pump housing.
AT-01982 AT-01980
2) Take out the oil pump body.
2) Remove the retainer plate, drive plate and driven plate. 3) Using the ST1, ST2 and ST3, remove the snap ring. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
ST1 ST2
D: ASSEMBLY
1. FRONT BRAKE
1) Apply ATF to D-ring, and then install it to the front brake piston. 2) Install the front brake piston to oil pump cover. NOTE: Install by aligning the mark on front brake piston surface with the oil pump cover rib.
ST3 AT-01981
4) Remove the retainer and return spring. 5) Remove the front brake piston using compressed air.
AT-02350 AT-02349
3) Install the retainer and return spring.
6) Remove the D-ring from front brake piston.
5AT-84
Oil Pump Cover

4) Install the front brake piston assembly using ST1, ST2 and ST3. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
ST1 ST2
8) Remove the snap ring, replace the drive plate used in measurement of clearance with the retainer plate, and then reassemble.
2. OIL PUMP
1) Apply ATF to oil pump assembly, and then install it to oil pump housing. 2) Install the O-ring to oil pump cover. 3) Install the oil pump housing to the oil pump cover. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb)
ST3 AT-01981
5) Install the genuine driven plate instead of retainer plate, and temporarily assemble the drive plate and driven plate. Part No. 31536AA290 Driven plate 6) Install the snap ring.
AT-01982
AT-01980
7) Measure the clearance between retainer plate and snap ring, and then select the suitable retainer plate from table. Front brake clearance specification: 0.7 1.1 mm (0.028 0.043 in)
AT-01983
Front brake retainer plate Part No. Thickness mm (in) 31567AB130 3.4 (0.134) 31567AB140 3.6 (0.142) 31567AB150 3.8 (0.150) 31567AB160 4.0 (0.157)
5AT-85
Oil Pump Cover

E: INSPECTION
1. FRONT BRAKE
Check the following items. Drive plate facing for wear and damage Snap ring for wear, return spring for damage, and retainer for damage Piston for damage D-ring for damage
(2) Side clearance Set a depth gauge to oil pump housing, then measure the oil pump housing-to-rotor clearance. Side clearance: 0.02 0.045 mm (0.0008 0.0018 in)
(A)
2. OIL PUMP
Check the following items. Oil pump cover and oil seal for breakage or damage Oil pump body for scratch or damage 1) Check the seal ring and oil seal for breaks and damage. 2) Check other parts for dents or faults. 3) Oil pump rotor assembly selection (1) Tip clearance Install the inner rotor and outer rotor to oil pump housing. With rotor gears facing each other, measure the crest-to-crest clearance. Tip clearance: 0.02 0.15 mm (0.0008 0.0059 in)
(A) (B) (C)
(C)
(B) AT-01978
(A) Depth gauge (B) Inner rotor (C) Outer rotor
(3) If the depth and/or side clearance are not within the specification, replace the rotor assembly.
Part No. 15008AA130 15008AA140 15008AA150 Oil pump rotor assembly Thickness mm (in) 11.37 11.38 (0.4476 0.4480) 11.38 11.39 (0.4480 0.4484) 11.39 11.40 (0.4484 0.4488)
Measure the total end play and adjust it to be within specifications. <Ref. to 5AT-107, ADJUSTMENT, AT Main Case.>
AT-01977
(A) Thickness gauge (B) Inner rotor (C) Outer rotor
5AT-86


A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter assembly. <Ref. to 5AT-67, REMOVAL, Torque Converter Assembly.> 3) Remove the transmission harness connector from stay. 4) Disconnect the air breather hose. <Ref. to 5AT65, REMOVAL, Air Breather Hose.> 5) Remove the oil charge pipe. <Ref. to 5AT-66, REMOVAL, Oil Charge Pipe.> 6) Remove the ATF inlet and outlet pipes. <Ref. to 5AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 7) Separate the converter case and transmission case. <Ref. to 5AT-81, REMOVAL, Converter Case.> 8) Remove the drive pinion shaft mounting bolts, and then remove the drive pinion shaft assembly from oil pump cover.
B: INSTALLATION
1) Assemble the drive pinion assembly to oil pump cover. NOTE: Be careful not to bend the shim. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
AT-01984
AT-01984
9) Remove the oil pump cover from AT main case. <Ref. to 5AT-83, Oil Pump Cover.>
2) Adjust the tooth contact between drive pinion shaft assembly and the front differential side gear. <Ref. to 5AT-90, ADJUSTMENT, Drive Pinion Shaft Assembly.> 3) Join the converter case with the transmission case. <Ref. to 5AT-81, INSTALLATION, Converter Case.> 4) Install the transmission harness connector to the stay. 5) Install the ATF cooler pipe. <Ref. to 5AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 6) Install the oil charge pipe with O-ring. <Ref. to 5AT-66, INSTALLATION, Oil Charge Pipe.> 7) Install the torque converter assembly. <Ref. to 5AT-67, INSTALLATION, Torque Converter Assembly.> 8) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
5AT-87

C: DISASSEMBLY
1) Flatten the lock nut tab, and then remove the lock nut while holding the rear spline part of the shaft using ST1 and ST2. Pull out the drive pinion collar. ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER
D: ASSEMBLY
1) Measure the dimension A of the drive pinion shaft. ST 398643600 GAUGE
ST3
ST2 ST1
AT-00200
A Measured value
AT-00197
2) Remove the O-ring. 3) Separate the roller bearing and outer race from shaft using a press.
2) Using a press, press-fit the new roller bearing into the specified position. NOTE: If excessive force is applied to roller bearing, the roller bearing will not turn easily.
(A)
(A)
(B)
AT-00198 AT-00201
(A) Outer race
4) Separate the front roller bearing from the shaft using a press and the ST. ST 498517000 REPLACER
(A) Drive pinion shaft (B) Roller bearing
3) After fitting a new O-ring to the shaft, attach the drive pinion collar to the shaft.
(A) ST
AT-00199
(A) Front roller bearing
5AT-88

4) Tighten the new lock nuts using ST1, ST2 and ST3. Use the calculation below to calculate the tightening torque. T2 = L2/(L1 + L2) T1 T1: 116 Nm (11.8 kgf-m, 85.6 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example:
Torque wrench length m (in) 0.4 (15.75) 0.45 (17.72) 0.5 (19.69) 0.55 (21.65) Tightening torque Nm (kgf-m, ft-lb) 98 (10.0, 72.3) 100 (10.2, 73.8) 101 (10.3, 74.5) 102 (10.4, 75.2)
7) Measure the dimension B of the drive pinion shaft. ST 398643600 GAUGE
B AT-00204
B Measured value
ST1 ST2 ST3
18667AA010 499787700 499787500
HOLDER WRENCH ADAPTER
8) Calculate the thickness t mm (in) of the drive pinion shim. t = 6.5r0.0625 (0.2559r0.0025) (B A) 9) Select three or less shims from following table.
Part No. 31451AA180 31451AA190 31451AA200 31451AA210 31451AA220 31451AA230 Drive pinion shim Thickness mm (in) 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108)
NOTE: Attach ST2 to torque wrench as straight as possible.

ST3
ST2 L1 [m (in)] L2 [m (in)] ST1 AT-00202
E: INSPECTION
Make sure that all component parts are free of scratches, holes and other faults. Adjust the tooth alignment. <Ref. to 5AT-90, ADJUSTMENT, Drive Pinion Shaft Assembly.>
5) Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing. Starting torque: 7.6 38.1 N (0.775 3.88 kgf, 1.7 8.6 lb)
AT-00203
6) Crimp the locknut in 2 locations.
5AT-89

F: ADJUSTMENT
1) Remove the liquid gasket from the mating surface completely. 2) Install the converter case to oil pump cover, and secure them with tightening four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb) 3) Rotate the drive pinion a few times using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH
5) Apply lead-free red dye evenly on the surface of three to four teeth of the hypoid driven gear. Rotate the drive pinion in the leftward and rightward for several times. Remove the oil pump cover, and check the tooth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. <Ref. to 5AT-96, ADJUSTMENT, Front Differential Assembly.> Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)
(A)
ST1
ST2 (B)
MT-01401
AT-01985
4) Adjust the drive pinion and hypoid driven gear backlash. <Ref. to 5AT-96, ADJUSTMENT, Front Differential Assembly.>
AT-00208
Corrective action: Increase the thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
AT-00212
5AT-90

AT-00209
AT-00211
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion away from driven gear.
Corrective action: Increase the thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
AT-00213
AT-00212
6) If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Tighten the lock plate with specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-00210
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion away from driven gear.
AT-01988
(A) Lock plate
AT-00213
5AT-91


A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter assembly. <Ref. to 5AT-67, REMOVAL, Torque Converter Assembly.> 3) Remove the transmission harness connector from stay. 4) Remove the oil charge pipe. <Ref. to 5AT-66, REMOVAL, Oil Charge Pipe.> 5) Remove the ATF inlet and outlet pipes. <Ref. to 5AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 6) Separate the converter case from the transmission case. <Ref. to 5AT-81, REMOVAL, Converter Case.> 7) Remove the differential side retainers using ST. NOTE: Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case. ST 18630AA010 WRENCH COMPL RETAINER 8) Remove the differential assembly while being careful not to damage the attachment part of retainer.
5) Install the lock plate. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-01988
(A) Lock plate
B: INSTALLATION
1) When installing the front differential assembly to case, be careful not to damage the inside of case (particularly, the differential side retainer mating surface).
(A)
6) Install the converter case to the transmission case. <Ref. to 5AT-81, INSTALLATION, Converter Case.> 7) Install the transmission harness connector to the stay. 8) Install the ATF cooler pipe. <Ref. to 5AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 9) Install the oil charge pipe together with an Oring. <Ref. to 5AT-66, INSTALLATION, Oil Charge Pipe.> 10) Install the torque converter assembly. <Ref. to 5AT-67, INSTALLATION, Torque Converter Assembly.> 11) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
AT-01987
(A) Front differential ASSY
2) Install the O-ring to left and right side retainer. 3) Using the ST, install the side retainer. <Ref. to 5AT-92, INSTALLATION, Front Differential Assembly.> ST 18630AA010 WRENCH COMPL RETAINER 4) Adjust the backlash of the front differential. <Ref. to 5AT-96, ADJUSTMENT, Front Differential Assembly.>
5AT-92

C: DISASSEMBLY
1) Remove the taper roller bearing using the ST and the press. ST 498077000 REMOVER
2. SIDE RETAINER
NOTE: After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-ring. 1) Remove the O-ring.
AT-00219 AT-00216
2) Secure the case in a vise, remove the hypoid driven gear tightening bolts, and then separate the hypoid driven gear into case (RH) and case (LH).
(A)
(B) (C) MT-01454
AT-00217
3) Remove the split pin, and then remove the claw. ST 398527700 PULLER ASSY
3) Pull out the straight pin and shaft, and then remove the differential bevel gear, washer and differential bevel pinion.
AT-00221
(A) Claw (B) Split pin (C) Pin
(A)
AT-00218
5AT-93

4) Attach two claws to the outer race, and set the ST to side retainer. ST 398527700 PULLER ASSY
D: ASSEMBLY
1) Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft. 2) Attach the straight pin in the reverse direction.
AT-00222
(A) Shaft (B) Claw

(A)
5) Restore the removed claws to original position, and install the pin and split pin. 6) Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race. ST 398527700 PULLER ASSY NOTE: Replace the bearing inner and outer races as a single unit.
AT-00218
3) Install the washer and differential bevel gear to differential case (LH). Put the case on the differential case (RH), and assemble two cases. 4) Install the hypoid driven gear and secure by tightening the bolt. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A)
(B) (C) AT-00223
(A) Shaft (B) Side retainer (A) Hypoid driven gear (B) Differential case (RH) (C) Differential case (LH)
AT-00217
5AT-94

5) Measurement of backlash (Selection of washer) (1) Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft (2) Measure the gear backlash using ST1 and ST2, and then insert the ST2 though the access window of case. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE NOTE: Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. Fix the differential bevel pinion gear in place with a screwdriver covered with cloth or similar tool when measuring. Standard: 0.13 0.18 mm (0.0051 0.0071 in)
ST1
2. SIDE RETAINER
NOTE: Install the oil seal and O-ring of side retainer after the adjustment of backlash and tooth contact. 1) Install the bearing outer race to side retainer. 2) Install a new oil seal using ST. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Apply oil to the oil seal lips.
ST
AT-00226
3) Install a new O-ring.
ST2 AT-00224
(3) If the backlash is not within specification, select a washer from the table below.
Washer Part No. 803038021 803038022 803038023 Thickness mm (in) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)
AT-00219
E: INSPECTION
Check each component for scratches, damage or other faults. Measure the backlash, and then adjust it to be within specification. <Ref. to 5AT-96, ADJUSTMENT, Front Differential Assembly.>
6) Using the ST, install the taper roller bearing. ST 398487700 DRIFT
5AT-95

F: ADJUSTMENT
1) Using the ST, screw-in the retainer until resistance is felt. NOTE: Screw in the RH side slightly deeper than the LH side. ST 18630AA010 WRENCH COMPL RETAINER
6) Tighten the LH retainer by rotating the shaft until resistance is felt. Then loosen the retainer RH. Keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft no longer be turned. This is the zero state.
(A)
ST
AT-01986
(A) Retainer
AT-00227
2) Remove the oil pump cover. 3) Remove the liquid gasket from the mating surface completely. 4) Install the oil pump cover to converter case, and secure them with tightening four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb) 5) Rotate the drive pinion ten times or more using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH
7) After the zero state is established, loosen the retainer LH by 3 notches and secure it with the lock plate. Then loosen the retainer RH and retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the retainer RH further 1-3/4 notches. This sets the preload. Finally, secure the retainer with its lock plate.
(A)
AT-01988
(A) Lock plate

ST1 ST2
NOTE: Turning the retainer by one tooth changes the backlash approx. 0.05 mm (0.0020 in).
AT-01985
(A)
AT-01989
(A) 0.05 mm (0.0020 in)
5AT-96

8) Turn the drive pinion several times using ST1, and check to see if the backlash is within the specification using ST2, ST3, ST4 and ST5. ST1 499787700 WRENCH ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE ST4 499787500 ADAPTER ST5 498255400 PLATE Backlash: 0.13 0.18 mm (0.0051 0.0071 in) 9) Adjust the teeth contact of the front differential and drive shaft. <Ref. to 5AT-90, ADJUSTMENT, Drive Pinion Shaft Assembly.>
5AT-97
AT Main Case
35.AT Main Case

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter assembly. <Ref. to 5AT-67, REMOVAL, Torque Converter Assembly.> 3) Remove the transmission harness connector from stay. 4) Disconnect the air breather hose. <Ref. to 5AT65, REMOVAL, Air Breather Hose.> 5) Remove the oil charge pipe. <Ref. to 5AT-66, REMOVAL, Oil Charge Pipe.> 6) Remove the ATF inlet and outlet pipes. <Ref. to 5AT-62, REMOVAL, ATF Cooler Pipe and Hose.> 7) Remove the extension case. <Ref. to 5AT-68, REMOVAL, Extension Case.> 8) Remove the center differential carrier. <Ref. to 5AT-77, REMOVAL, Center Differential Carrier.> 9) Remove the reduction driven gear. <Ref. to 5AT74, REMOVAL, Reduction Driven Gear.> 10) Separate the converter case from the transmission case. <Ref. to 5AT-81, REMOVAL, Converter Case.> 11) Remove the control valve body. <Ref. to 5AT57, REMOVAL, Control Valve Body.> 12) Remove the oil pump cover. <Ref. to 5AT-83, REMOVAL, Oil Pump Cover.> NOTE: The input clutch pack assembly and front sun gear assembly are also removed together.
14) Remove the middle carrier assembly.
AT-01992
15) Remove the rear carrier assembly.
AT-01990
13) Remove the needle bearing of the middle carrier assembly.

AT-01993
AT-01991
5AT-98
AT Main Case
16) Remove the middle & rear sun gear assembly.
19) Remove the direct clutch assembly.
AT-01997
20) Remove the snap ring of reverse brake.
AT-01994
AT-01998
17) Remove the thrust needle bearing of high & low reverse clutch.
21) Remove the retaining plate. 22) Remove the leaf spring.
(A)
B'
AT-01995
18) Remove the high & low reverse clutch assembly.
B'
(A) AT-03364
AT-01996
(A) Leaf spring
23) Take out the drive plate, driven plate and dish plate.
5AT-99
AT Main Case
24) Remove the snap ring of the reverse brake spring retainer. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
27) Apply compressed air.
ST1 AT-02004
28) Remove the reverse brake piston.
ST2
ST3 AT-02005
29) Remove the thrust bearing and the seal ring.
AT-02000
25) Remove the spring retainer.

(A) (B) (A)
(A) AT-02001 (B) (A)
26) Remove the return spring.
AT-04307
(A) Thrust bearing (B) Seal ring

AT-02002
5AT-100
AT Main Case
B: INSTALLATION
1) Apply ATF to a new seal ring. 2) Install the thrust bearing and a new seal ring to the drum support.
5) Install the spring retainer and snap ring. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT
(A) (B) (A)
ST1
ST2 (A) (B) (A) ST3
AT-04307 AT-02000
(A) Thrust bearing (B) Seal ring
6) Install the dish plate. NOTE: When installing, make sure that the identification mark is facing the front side of transmission. 7) Install the drive plate and driven plate.
3) Install the reverse brake piston. NOTE: Apply ATF onto the piston sliding surface. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT 4) Install the return spring.
AT-02002
5AT-101
AT Main Case
8) Install the leaf spring.

(A)
11) Perform the clearance check of reverse brake. (1) Measure the clearance between retainer plate and snap ring using thickness gauge. Standard: 0.7 1.1 mm (0.028 0.043 in)
B'
B'
AT-02372
(2) If it is out of specification, select a suitable retainer plate from the following table and assemble it.
(A) AT-03364
(A) Leaf spring
9) Install the retaining plate. 10) Install the snap ring of the reverse brake.
Part No. 31567AB100 31567AB170 31567AB180 31567AB190 31567AB200
Retainer plate Thickness mm (in) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.0 (0.197)
12) Install the direct clutch assembly.
AT-01998 AT-01997
13) Install the high & low reverse clutch assembly.
AT-01996
5AT-102
AT Main Case
14) Install the thrust needle bearing of the high & low reverse clutch.
16) Install the rear carrier assembly.
AT-01995
15) Install the middle & rear sun gear assembly.
AT-01993
17) Install the middle carrier assembly.
AT-01994
AT-01992
5AT-103
AT Main Case
18) Install the thrust needle bearing of middle carrier assembly.
22) Install the oil pump cover. (1) Apply ATF to the O-ring of input clutch shaft. (2) Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing with your hand.
AT-01991
19) Measure the total end play, and select the bearing. <Ref. to 5AT-107, ADJUSTMENT, AT Main Case.> 20) Install the impact clutch pack assembly to oil pump cover.
(B)
AT-01990
(3) Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear.
(A) AT-02006 (A) AT-02092
(A) Impact clutch pack ASSY (B) Front sun gear ASSY (A) Drive pinion shaft
21) Turn the transmission sideways.
(4) Protect the input clutch shaft with a cloth, and rotate to engage the spline of the input clutch and rear carrier using pliers. NOTE: Work with pressing the oil pump cover.
(A)
AT-02046
(A) Cloth
5AT-104
AT Main Case
(5) Combine the oil pump cover with transmission main case. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
C: DISASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
1) Remove the front sun gear.
AT-01976
AT-02007
23) Install the center differential carrier. <Ref. to 5AT-77, INSTALLATION, Center Differential Carrier.> 24) Install the reduction driven gear. <Ref. to 5AT74, INSTALLATION, Reduction Driven Gear.> 25) Install the extension case. <Ref. to 5AT-68, INSTALLATION, Extension Case.> 26) Install the control valve body. <Ref. to 5AT-58, INSTALLATION, Control Valve Body.> 27) Install the converter case assembly to the transmission case assembly. <Ref. to 5AT-81, INSTALLATION, Converter Case.> 28) Install the air breather hose. <Ref. to 5AT-65, INSTALLATION, Air Breather Hose.> 29) Install the ATF cooler pipe. <Ref. to 5AT-63, INSTALLATION, ATF Cooler Pipe and Hose.> 30) Install the oil charge pipe together with an Oring. <Ref. to 5AT-66, INSTALLATION, Oil Charge Pipe.> 31) Install the torque converter assembly. <Ref. to 5AT-67, INSTALLATION, Torque Converter Assembly.> 32) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.> 33) Perform Clear Memory 2 operation. <Ref. to 5AT(diag)-20, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> 34) Execute the learning control promotion. <Ref. to 5AT(diag)-24, PROCEDURE, Learning Control.> 35) Perform the inspection at the end of repair work, and make sure there is no faulty as below; Excessive shift shock Oil leakage from the transmission body, etc. Occurrence of noise caused by interference etc.
2) Remove the thrust bearing. 3) Remove the snap ring, and then remove the front carrier.
AT-02008
4) Remove the input clutch assembly from rear internal gear.
AT-02009
5AT-105
AT Main Case
D: ASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
1) Assemble the input clutch assembly to rear internal gear.
E: INSPECTION
1. FRONT, MIDDLE & REAR PLANETARY CARRIER ASSEMBLY
Check the following items. Visually inspect the tooth surface of planetary gear, and replace with new part if damaged, broken or excessively worn. Inspect the planetary carrier body for damage or breakage.
2. INPUT CLUTCH
Check the clearance of the input clutch. Measure the clearance L between snap ring and retaining plate using a thickness gauge. If it is out of specification, replace the entire direct clutch assembly. Check for damage on the drive plate, driven plate and snap ring, and replace the entire input clutch assembly if damaged. Standard: 0.7 1.1 mm (0.028 0.043 in)
L
AT-02009
2) Install the front carrier, and then install the snap ring.
AT-02008
3) Install the thrust bearing. 4) Install the front sun gear.

AT-03259
L Measured value
AT-02007
5AT-106
AT Main Case
3. HIGH & LOW REVERSE CLUTCH ASSEMBLY

Check the clearance of the high & low reverse clutch. Measure the clearance L between snap ring and retaining plate using a thickness gauge. If it is out of specification, replace the entire high & low reverse clutch assembly. Check for damage on the drive plate, driven plate and snap ring, and replace the entire high & low reverse clutch assembly if damaged. Standard: 1.8 2.2 mm (0.071 0.087 in)
L
5. REVERSE BRAKE
Check the following items. Drive plate facing for wear or damage Snap ring for wear, return spring for breakage, and spring retainer for deformation Lip seal and D-ring for damage Piston operation
F: ADJUSTMENT
1) Using the ST, measure the height A from the AT main case mating surface to convex surface of oil pump cover. ST 499575400 GAUGE
ST
AT-02012 AT-02010
L Measured value
A Measured value
4. DIRECT CLUTCH ASSEMBLY

Check the clearance of direct clutch. Measure the clearance L between snap ring and retaining plate using a thickness gauge. If it is out of specification, replace them as direct clutch assembly. Check for damage on the drive plate, driven plate and snap ring, and replace the entire direct clutch assembly if damaged. Standard: 0.6 1.0 mm (0.024 0.039 in)
L
2) Using the ST, measure the depth B from the convex surface of oil pump cover to thrust bearing transferring surface. ST 499575400 GAUGE
ST
AT-02013
B Measured value
3) Calculate the measured value from step 1) and 2), and then set the calculated value as C. Calculation formula: C = A B
AT-02011
L Measured value
5AT-107
AT Main Case
4) Using the ST, measure the depth D from the AT main case mating surface to thrust bearing transferring surface of front sun gear. ST 499575400 GAUGE
ST
AT-02014
D Measured value
5) Set the value as E which subtract the thickness of ST (499575400 GAUGE) from the measured value on step 4). Calculation: E (mm) = D 15 [E (in) = D 0.59] 6) Calculation formula: Select one thrust bearing from the table to adjust clearance within 0.25 0.55 mm (0.0098 0.0217 in). When clearances are 0.25 mm (0.0098 in): T (mm) = E C + 0.03 [T (in) = E C + 0.0012] When clearances are 0.55 mm (0.0217 in): T (mm) = E C + 0.27 [T (in) = E C + 0.0106] T: Thrust bearing thickness C: Distance from oil pump cover mating surface to rear end of oil pump cover E: Depth from mating surface of AT main case to bearing surface of front sun gear NOTE: Calculation formula for T above is applied when measuring with the ST (499575400 GAUGE). In the calculation without using ST, substitute the thickness of collar used to calculate the value E on step 5).
Part No. 806548020 606548030 806548040 806548050 806548060 806548070 Thrust bearing Thickness mm (in) 3.2 (0.126) 3.4 (0.134) 3.6 (0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165)
5AT-108

36.Transmission Control Device

A: REMOVAL
1) Remove the transmission assembly from vehicle body. <Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.> 2) Pull out the torque converter assembly. <Ref. to 5AT-67, REMOVAL, Torque Converter Assembly.> 3) Lift up the lever on the rear side of transmission harness connector, and then disconnect it from the stay. 4) Disconnect the air breather hose. <Ref. to 5AT65, REMOVAL, Air Breather Hose.> 5) Wrap vinyl tape around the nipple attached to the air breather hose. 6) Remove the pitching stopper bracket. 7) Remove the control valve body assembly. <Ref. to 5AT-57, REMOVAL, Control Valve Body.> 8) Pull out the straight pin of manual plate.
10) Remove the detent spring.
AT-00307
AT-00305
9) Remove the bolts securing range select lever, and then remove the select lever, manual plate and parking rod. NOTE: Be careful not to damage the lips of press-fitted oil seal in the case.
AT-00306
(A) (B) (C) (D)
5AT-109

B: INSTALLATION
1) Install the detent spring to the transmission case. Tightening torque: 7 Nm (0.7 kgf-m, 5.2 ft-lb)
4) Insert the spring pin to the manual plate.
AT-00305
5) Install the oil pan and the control valve body assembly. <Ref. to 5AT-58, INSTALLATION, Control Valve Body.> 6) Install the pitching stopper bracket.
AT-00307
2) Insert the range select lever, and tighten the bolts. Tightening torque: 6 Nm (0.6 kgf-m, 4.4 ft-lb)
Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb) 7) Insert the transmission connector to the stay. 8) Install the air breather hose. <Ref. to 5AT-65, INSTALLATION, Air Breather Hose.> 9) Install the torque converter assembly. <Ref. to 5AT-67, INSTALLATION, Torque Converter Assembly.> 10) Install the transmission assembly to the vehicle. <Ref. to 5AT-43, INSTALLATION, Automatic Transmission Assembly.>
C: INSPECTION
AT-00308
Make sure the manual lever and detent spring are not worn or otherwise damaged.
3) Insert the manual plate and parking rod.
AT-00306
(A) (B) (C) (D)
5AT-110


A: PROCEDURE
1 Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to 5AT(diag)-4, Check List for Interview.> 2) Check the following items which may be affecting the AT trouble. General inspection <Ref. to 5AT(diag)-5, INSPECTION, General Description.> Oil leakage Stall speed test <Ref. to 5AT-32, Stall Test.> Line pressure test <Ref. to 5AT-35, Line Pressure Test.> Transfer clutch pressure test <Ref. to 5AT-37, Transfer Clutch Pressure Test.> Time lag test <Ref. to 5AT-34, Time Lag Test.> Road test <Ref. to 5AT-31, Road Test.> Inhibitor switch <Ref. to 5AT-51, Inhibitor Switch.> CHECK AT OIL TEMP LIGHT. After the ignition switch is turned to ON, wait for at least 2 seconds. CHECK AT OIL TEMP LIGHT. 1) Turn the ignition switch to OFF. 2) Check the AT OIL TEMP light. <Ref. to 5AT(diag)-27, INSPECTION, AT OIL TEMP Warning Light Display.> 3) After the ignition switch is turned to ON, wait for at least 2 seconds. CHECK DTC. Read the DTC. <Ref. to 5AT(diag)-21, OPERATION, Read Diagnostic Trouble Code (DTC).> NOTE: If the communication function of Subaru Select Monitor cannot be executed normally, check the communication circuit. <Ref. to 5AT(diag)29, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, Diagnostic Procedure for Subaru Select Monitor Communication.> PERFORM GENERAL DIAGNOSTICS. 1) Inspect using Diagnostic Procedure without Diagnostic Trouble Code (DTC). <Ref. to 5AT(diag)-106, Diagnostic Procedure without Diagnostic Trouble Code (DTC).> 2) Perform the Clear Memory Mode. 3) Perform the Inspection Mode. <Ref. to 5AT(diag)-22, Inspection Mode.> 4) Display DTC. Check Yes Is the item that is thought to Go to step 2. influence the AT problem working properly? No Repair or replace each item.
Does the AT OIL TEMP light illuminate? Does the AT OIL TEMP light blink?
Go to step 4.
Go to step 3.
Go to step 4.
Go to step 5.
Is DTC displayed?
Go to step 6. NOTE: Record all DTC.
Go to step 5.
Is DTC displayed?
Go to step 6.
Inspect using General Diagnostic Table. <Ref. to 5AT(diag)-113, General Diagnostic Table.>
5AT(diag)-2

Step Check PERFORM DIAGNOSIS. Is DTC displayed? 1) Inspect using Diagnostic Procedure with Diagnostic Trouble Code (DTC). <Ref. to 5AT(diag)-35, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> NOTE: For DTC table, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 5AT(diag)-32, List of Diagnostic Trouble Code (DTC).> 2) Repair the trouble cause. 3) Perform the Clear Memory Mode. 4) Perform the Inspection Mode. <Ref. to 5AT(diag)-22, Inspection Mode.> 5) Display DTC. Yes Inspect using Diagnostic Procedure with Diagnostic Trouble Code (DTC). <Ref. to 5AT(diag)-35, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> No Inspect using General Diagnostic Table. <Ref. to 5AT(diag)-113, General Diagnostic Table.>
5AT(diag)-3


A: CHECK
Check the following items when a problem has occurred. NOTE: Use copies of this page for interviewing customers.
Customers name Date of purchase Date of repair Transmission model Odometer reading Symptom
Transmission
V.I.N. km (miles)
( Frequency Weather ( Place ( Ambient air temperature Vehicle speed AT warning light (AT OIL TEMP light) Select lever position Driving condition
No up-shift No down-shift No kick down Vehicle does not move ( Any position Particular position) Lock-up malfunction Noise or vibration Shift shock or slip Select lever does not move Others ) Continuous Intermittent ( times a day) Fine Cloudy Rainy Snowy Others ) Highland Suburbs Inner city Uphill Rough road Others ) Hot Warm Cool Cold km/h (MPH) Blinks continuously P R N Not affected At racing While decelerating ON OFF D Does not blink Manual mode While idling At starting While cruising While accelerating While turning RH/ LH)
( Manual mode
5AT(diag)-4
General Description
A: CAUTION
The airbag system wiring harness is routed near the TCM. CAUTION: All the airbag system wiring harnesses and connectors are colored yellow. Do not use an electric test equipment to check these circuits. Be careful not to damage the airbag system wiring harness when performing diagnostics or servicing the TCM.
3. ATF LEVEL
Make sure that ATF level is the specified amount. <Ref. to 5AT-28, INSPECTION, Automatic Transmission Fluid.>
F HOT
(A) (C) (D)
(B) (A)
(C)
COLD L
(D)
(E)
PI-00362
2. MEASUREMENT
When measuring the voltage and resistance of the ECM, TCM or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert a pin of more than 0.65 mm (0.026 in) diameter.
(A) (B) (C) (D) (E)
Oil level gauge Inspection position when HOT Upper level Lower level Inspection position when COLD
B: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of the electrolyte. Standard voltage: 12 V or more Specific gravity: 1.260 or more
4. FRONT DIFFERENTIAL OIL LEVEL

Make sure the front differential oil level is the specified amount. <Ref. to 5AT-30, INSPECTION, Differential Gear Oil.>
(A) (A)
F L
(B) (C)
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened securely. Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
PI-00184
AT-01464
5AT(diag)-5
General Description
5. OPERATION OF SHIFT SELECT LEVER

Make sure there is no noise, dragging or contact pattern in each select lever range. WARNING: Stop the engine while checking operation of the select lever.
AT-02048
5AT(diag)-6
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
2. GENERAL TOOL
5AT(diag)-7


A: LOCATION
1. CONTROL MODULE
(1)
(3)
(4) (2)
(5) AT-02049
(1) (2)
Engine control module (ECM) AT OIL TEMP light (AT warning light)
(3)
Transmission control module (TCM)
(4) (5)
Data link connector Body integrated unit
5AT(diag)-8

(1)
(2) AT-02051 AT-03759
(4)
(3)
AT-02053
AT-02052
(5)
AT-04405
5AT(diag)-9

2. SENSOR
(6) (1)
(3),(5),(7)
(2)
(4) AT-04263
(1) (2) (3)
Accelerator pedal position sensor Front vehicle speed sensor Inhibitor switch
(4) (5)
Rear vehicle speed sensor Turbine speed sensor 1
(6) (7)
ATF temperature sensor Turbine speed sensor 2
5AT(diag)-10

(2) (1)
AT-00375
AT-03281
(5)
(4)
(3) AT-04264 AT-03282
(7) (6)
AT-04265
AT-04266
5AT(diag)-11

3. SOLENOID
(5) (3) (6) (4) (1)
(7)
(8)
(2)
AT-04871
(1) (2)
High & low reverse clutch linear solenoid Direct clutch linear solenoid
(3) (4) (5)
Front brake linear solenoid Input clutch linear solenoid Line pressure linear solenoid
(6) (7) (8)
Lock-up pressure linear solenoid Transfer linear solenoid Forward brake linear solenoid
5AT(diag)-12

4. OIL PRESSURE SWITCH

(2)
(1)
(3)
(4)
(5)
AT-04872
(1) (2)
Front brake oil pressure switch Input clutch oil pressure switch
(3)
High & low reverse clutch oil pressure switch
(4) (5)
Direct clutch oil pressure switch Forward brake oil pressure switch
5AT(diag)-13

5. Transmission Control Module (TCM) I/O Signal

TO
B55 6 16 15 27 26 35 34
TO
B54
7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28
5 4 3 2 1 14 13 12 11 10 9 8 7 25 24 23 22 21 20 19 18 17 33 32 31 30 29 28
AT-03733
NOTE: The measurement should be performed after warming up.

Item Connector Terminal No. No. Measuring condition Engine ON, P range, accelerator OFF, brake ON Measured value Resistance between terminal Remarks and chassis ground 39: Drive frequency: (ATF temperature 300 Hz 20C (68F))
P/L solenoid output
B54
3.5 7.5 V
I/C oil pressure switch input Power GND CAN communication line (+) CAN communication line ()
B54
20
While driving at 1st-3rd 6 V or more of manual mode While driving at 4th or Less than 1.5 V 5th of manual mode Always Ignition switch ON ATF oil temperature 20C (68F) Approx. 0 V 3.5 4.3 V 2.5 7.0 k: When measuring the resistance, be sure to disconnect the connector and perform the measurement with TCM alone.
B54 B55 B55
12 21 20
ATF temperature sensor 1 input
B54
17
Ignition switch ON ATF oil temperature 80C (176F)
1 2.2 V
0.3 0.8 k:
Backup power supply
B55
24
I/C solenoid output
B54
Ignition switch ON 8 V or more Ignition switch OFF While driving at 1st-3rd 5 V or more of manual mode While driving at 4th or Less than 1.5 V 5th of manual mode
39: Drive frequency: (ATF temperature 300 Hz 20C (68F))
5AT(diag)-14

Resistance between terminal and chassis ground
Item
Connector Terminal No. No.
Measuring condition While driving at 2nd of manual mode While driving at 1st, 3rd-5th of manual mode Always Always While driving at other than 4th of manual mode While driving at 4th of manual mode When lock-up
Measured value
Remarks
5 V or more Less than 1.5 V Approx. 0 V Approx. 0 V 5 V or more Less than 1.5 V 3 V or more Less than 1 V 5 V or more
H & LR/C solenoid output
B54
39: Drive frequency: (ATF temperature 300 Hz 20C (68F)) 39: Drive frequency: (ATF temperature 300 Hz 20C (68F)) 39: Drive frequency: (ATF temperature 300 Hz 20C (68F)) 39: Drive frequency: (ATF temperature 300 Hz 20C (68F))
Power GND Analog GND
B54 B54
13 18
Fr/B solenoid output
B54
L/U solenoid output
B54
When not lock-up While driving at 1st or 5th of manual mode
D/C solenoid output
B54
While driving at 2nd-4th Less than 1.5 V of manual mode While driving at 1st or 6 V or more 5th of manual mode While driving at 2nd-4th Less than 1.5 V of manual mode Ignition switch ON 8 V or more Ignition switch OFF Always While driving at 2nd of manual mode While driving at 3rd-5th of manual mode While driving at 1st or 2nd of manual mode While driving at 3rd-5th of manual mode While driving at 1st or 2nd of manual mode While driving at 3rd-5th of manual mode While driving at 2nd and 20 km/h (12 MPH) of manual mode While driving at 4th and 80 km/h (50 MPH) of manual mode Ignition switch ON, P range Ignition switch ON, N range Less than 1 V Approx. 0 V 6 V or more
D/C oil pressure switch input Subaru Select Monitor communication line Sensor GND (analog) H&LR/C oil pressure switch input
B54
22
B55 B54
8 16
B54
14
Less than 1.5 V 5 V or more Less than 1.5 V Less than 1.5 V 6 V or more Approx. 500 700 rpm Approx. 2,000 2,500 rpm Less than 0.5 V 5 V or more Use the Subaru Select Monitor. Use the Subaru Select Monitor.
Fwd/B solenoid output
B54
19
Drive frequency: 300 Hz
Fwd/B oil pressure switch input
B54
21
Front vehicle speed sensor input
B54
24
Inhibitor switch 1 input
B54
5AT(diag)-15

Item
Measuring condition Ignition switch ON, P range Ignition switch ON, D range Ignition switch ON Ignition switch ON Ignition switch OFF While driving at 2nd and 20 km/h (12 MPH) of manual mode While driving at 4th and 80 km/h (50 MPH) of manual mode While driving at other than 4th of manual mode While driving at 4th of manual mode 2nd of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor) 4th of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor) Ignition switch ON (when lateral G sensor is in horizontal position) Ignition switch ON, R range Ignition switch ON, D range Ignition switch ON Ignition switch OFF Ignition switch ON Ignition switch OFF Ignition switch ON, P range Ignition switch ON, D range Ignition switch ON, R range Ignition switch ON, other than R range
Measured value
Remarks
Inhibitor switch 2 input Lateral G sensor signal Ignition power supply
5 V or more Less than 0.5 V 2.0 3.0 8 V or more Less than 1 V Approx. 500 700 rpm Approx. 2,000 2,500 rpm Less than 1.5 V 6 V or more Use the Subaru Select Monitor. Approx. 1,900 2,100 rpm Use the Subaru Select Monitor. Use the Subaru Select Monitor. Use the Subaru Select Monitor.
B54
B55 B54
9 27
Rear vehicle speed sensor input
B54
23
Fr/B oil pressure switch input
B54
15
Approx. 0 rpm
Turbine speed sensor 1 input
B54
26
Lateral G sensor power supply output
B55
4.75 5.25 5 V or more
B54
10
Less than 0.5 V Approx. 0 V Approx. 0 V Less than 0.5 V 5 V or more Less than 1 V 8 V or more 90 110 : (ATF temperature 25C (77F))
Control GND1 Control GND2
B55 B55
23 22
B54
11
Back-up light relay output
B55
13
AWD solenoid output
B54
Engine ON, P range or N range, Less than 1 V accelerator OFF Engine ON, D range, accelerator OFF, 2 V or more brake ON
39: Drive frequency: (ATF temperature 300 Hz 20C (68F))
5AT(diag)-16

Item
Measuring condition 2nd of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor) 4th of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor) Ignition switch ON, Other than P range or N range Ignition switch ON, P range or N range Ignition switch ON Ignition switch OFF Ignition switch ON Ignition switch OFF Ignition switch ON Ignition switch OFF Ignition switch ON Ignition switch OFF
Measured value
Remarks
Approx. 1,200 1,500 rpm
Use the Subaru Select Monitor.
Turbine speed sensor 2 input
B54
25
Approx. 1,900 2,100 rpm
Use the Subaru Select Monitor.
8 V or more Less than 1 V 8 V or more 8 V or more Less than 1 V 8 V or more Less than 1 V 8 V or more
PN signal output
B55
11
Ignition power supply 1 Ignition power supply 2 Ignition power supply 3 Ignition power supply 4
B55 B55 B55 B55
26 19 18 25
5AT(diag)-17


A: OPERATION
1) Prepare the Subaru Select Monitor kit. <Ref. to 5AT(diag)-7, PREPARATION TOOL, General Description.> 2) Prepare PC with Subaru Select Monitor installed. 3) Connect the USB cable between SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 4) Connect the diagnosis cable to SDI. 5) Connect SDI to data link connector located in the lower portion of the instrument panel (on the drivers side).

1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Transmission Control System}. 3) After transmission type information pops up, select [OK]. 4) On the Transmission Diagnosis display, select the {Current Data Display & Save}. 5) On the Current Data Display & Save display, select the {Normal sampling}.
AT-04371
CAUTION: Do not connect scan tools other than the Subaru Select Monitor. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. 8) On the Main Menu display, select the {Each System Check}. 9) On the System Selection Menu display, select the {Transmission Control System}. 10) After transmission type information pops up, select [OK]. 11) On the Transmission Diagnosis display, select the {Diagnostic Code(s) Display}. 12) On the Diagnostic Code(s) Display display, select the {Temporary Diagnostic Code(s)} or {Memorized Diagnostic Code(s)}
5AT(diag)-18

6) Using the scroll key, scroll the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Item Engine speed signal Battery voltage Accelerator pedal position sensor Front vehicle speed sensor signal Gear position Turbine speed sensor signal Rear vehicle speed sensor signal Lateral G sensor ATF temperature sensor signal Turbine speed sensor 1 signal Turbine speed sensor 2 signal High & low reverse clutch solenoid indicator current Direct clutch solenoid indicator current Front brake solenoid indicator current Input clutch solenoid indicator current Line pressure solenoid indicator current Lock-up solenoid indicator current Transfer solenoid indicator current High & low reverse clutch solenoid target oil pressure Direct clutch solenoid target oil pressure Front brake solenoid target oil pressure Input clutch solenoid target oil pressure Line pressure solenoid target oil pressure Lock-up solenoid target oil pressure Transfer solenoid target oil pressure Ignition switch SPORT shift signal Cruise control signal Down shift signal Stop light switch signal Up shift signal Drive range signal Reverse range signal Diagnosis light output signal ATF oil temperature light signal Parking range signal P/N range output signal Neutral range signal Inhibitor switch 1 input signal Inhibitor switch 2 input signal Inhibitor switch 3 input signal Inhibitor switch 4 input signal Backup light relay output signal High & low reverse clutch oil pressure switch input signal Direct clutch oil pressure switch input signal Front brake oil pressure switch input signal Input clutch oil pressure switch input signal Forward brake indicator current Display Engine Speed Battery Voltage Accel. Opening Angle Front Wheel Speed Gear Position Turbine Revolution Speed Rear Wheel Speed Lateral G Sensor ATF Temp. AT Turbine Speed 1 AT Turbine Speed 2 H&LR/C Solenoid Current D/C Solenoid Current F/B Solenoid Current I/C Solenoid Current P/L Solenoid Current L/U Solenoid Current AWD Solenoid Current H&LR/C Solenoid Pressure D/C Solenoid Pressure F/B Solenoid Pressure I/C Solenoid Pressure P/L Solenoid Pressure L/U Solenoid Pressure AWD Solenoid Pressure Ignition Switch Tiptronic Mode Switch Cruise Control Signal Down Switch Stop Light Switch Up Switch D Range Signal R Range Signal Diagnosis Lamp ATF Temperature Lamp P Range P/N Signal N Range Inhibitor SW 1 Inhibitor SW 2 Inhibitor SW 3 Inhibitor SW 4 Back Lamp Relay H&LR/C Fluid Pressure D/C Fluid Pressure F/B Fluid Pressure I/C Fluid Pressure Fwd/B solenoid current Unit of measure rpm V % km/h rpm km/h V C rpm rpm A A A A A A A kPa kPa kPa kPa kPa kPa kPa ON Input or OFF Input ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF High or Low High or Low High or Low High or Low ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF A
5AT(diag)-19

Item Forward brake solenoid input signal Forward brake oil pressure switch input signal Display Fwd/B solenoid target pressure Fwd/B hydraulic pressure SW Unit of measure Kpa ON or OFF
NOTE: For detailed operation procedure, refer to the PC application help for Subaru Select Monitor
3. CLEAR MEMORY MODE

1) Shift the select lever to P range. 2) On the Main Menu display, select the {Each System Check}. 3) On the System Selection Menu display, select the {Transmission Control System}. 4) After transmission type information pops up, select [OK]. 5) On the Transmission Diagnosis display, select the {Clearing Memory}. 6) When Done. Turn ignition switch OFF pops up, select [OK]. 7) Turn Subaru Select Monitor and ignition switch to OFF. To turn the ignition switch to ON again, wait for 10 seconds or more. NOTE: To clear the previous DTC, use {Clearing Memory}, and to clear the learned value, use {Clear Memories 2}. For detailed operation procedure, refer to the PC application help for Subaru Select Monitor
5AT(diag)-20


A: OPERATION
Refer to Subaru Select Monitor for information about how to obtain and understand DTC. <Ref. to 5AT(diag)-18, OPERATION, Subaru Select Monitor.>
5AT(diag)-21
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING: Observe the traffic law when driving on public roads. 1) Shift the select lever to D range, and then drive the vehicle with changing the gear from 1st to 5th. 2) When driving the vehicle at 5th speed of D range, set the gear to manual mode and drive the vehicle by downshifting using of the select lever from 5th o 4th, 4th o 3rd, 3rd o 2nd, and 2nd o 1st. NOTE: At shifting down, drive the vehicle at least 10 seconds in each speed. 3) Shift the select lever to R range and drive the vehicle for 2 seconds or more.
5AT(diag)-22
Clear Memory Mode


A: OPERATION
Use Subaru Select Monitor to clear DTC. <Ref. to 5AT(diag)-20, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> NOTE: DTC cannot be cleared without using Subaru Select Monitor.
5AT(diag)-23
Learning Control
10.Learning Control
Follow the messages displayed on the Subaru Select Monitor when working. When the following work is performed, perform learning for the transmission. Replacement of TCM/Replacement or disassembly of transmission assembly/Replacement of control valve body/Performing Clear Memories 2 is executed.
B: PROCEDURE
1. PREPARATION FOR LEARNING CONTROL
1) Warm-up or cool down until the ATF temperature displayed on the Subaru Select Monitor reaches 60 80C (140 176 F). 2) Shift the select lever to P range. 3) Fully apply the parking brake. 4) Lift up the vehicle. CAUTION: Be sure to keep the lowest edge of the tires 30 cm or more off the ground because the vehicle vibrates during the work. 5) Connect the Subaru Select Monitor to the data link connector. 6) Turn the ignition switch to ON. (Press push button ignition switch twice without depressing brake pedal for push button start.) 7) Select {Learning and inspection mode related to AT} on the Transmission Diagnosis display screen of Subaru Select Monitor. 8) Select {AT learning mode} on the Learning and inspection mode related to AT display screen of Subaru Select Monitor. 9) Perform the procedures according to the message displayed on the Subaru Select Monitor.
5AT(diag)-24
Learning Control
2. SIMPLE LEARNING
NOTE: Simple learning is performed with the vehicle lifted, without actually running the vehicle. CAUTION: Do not turn the power of the Subaru Select Monitor OFF and do not disconnect the data link connector during the operation. 1) Follow the messages displayed on the Subaru Select Monitor screen when working. NOTE: During SHIFT control system learning in progress and AWD control system learning in progress, AT OIL TEMP light in the combination meter starts flashing at 2 Hz and the learning operation starts. The following message is displayed on the screen when the AT OIL TEMP light turns off. If operation ended abnormally during learning, AT OIL TEMP light flashes at 4 Hz. 2) AT learning normally ended. is displayed, simple AT learning is completed. NOTE: If communication error occurs during learning, retry the AT learning mode from the beginning. If the message Execute AT learning again after fixing troubles of the vehicle is displayed during learning, select [OK] to display the List of Diagnostics Trouble Code. After repairing the locations indicated by the DTC, start the AT learning mode over from the beginning. If the message AT learning ended abnormally is displayed, start the AT learning mode over from the beginning.
Message AT learning ended abnormally Main cause of abnormal incompletion Fault is detected during AT learning. The accelerator pedal is depressed during AT learning. Operation which is not directed is performed during AT learning. Brake pedal not stepped on firmly enough. Parking brake not applied strongly enough. Abnormal idle speed increase, etc.
For detailed operation procedure, refer to the PC application help for Subaru Select Monitor
3. DRIVING CHECK
Drive actually and check for shifting shock or faults. If shifting shock is felt, perform the learning operation again. If reducing of shifting shock is not felt, recheck that other parts are normal.
5AT(diag)-25

11.AT OIL TEMP Warning Light Display

A: OPERATION
When any on-board diagnostics item is malfunctioning, the AT OIL TEMP light blinks from the time the malfunction is detected after starting the engine until the ignition switch is turned OFF. The malfunctioning part or unit can be determined by a DTC during the on-board diagnostics operation. Problems which occurred previously can also be identified through the memory function. If the AT OIL TEMP light does not show a problem (although a problem is occurring), the problem can be determined by checking the performance characteristics of each sensor using Subaru Select Monitor. Indicator light signal patterns are as shown in the figure. When the AT OIL TEMP light does not operate normally but no DTC is stored, perform the AT OIL TEMP light inspection. <Ref. to 5AT(diag)-27, INSPECTION, AT OIL TEMP Warning Light Display.>
(A) (1)
(2)
(B) (1) (3) (2) (4) (C) (1) (3) (2) (5)
AT-01750
(A) (1) (2)
Ignition switch (engine OFF) ON OFF
(B) (3) (4)
Normal (engine ON) 2 seconds 0.25 seconds
(C) (5)
Faulty (engine ON) Blink
5AT(diag)-26

B: INSPECTION
DIAGNOSIS: AT OIL TEMP light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), AT OIL TEMP light does not illuminate. WIRING DIAGRAM:
i10 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AT OIL TEMP COMBINATION METER
No. 5
MICRO COMPUTER
IGNITION SWITCH CAN TRANSCEIVER & RECEIVER
i10
A:
i84
SBF-6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
WN WN
21
MAIN SBF
ON
ON
22
B: B280 CAN JOINT CONNECTOR i106

ON ON
BATTERY
CAN JOINT CONNECTOR i107
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
WN WN
B55
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 BODY INTEGRATED UNIT B20 B30
E
A27 A26 i84
A:
B: B280
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
*2 *2
*1 *1
CAN JOINT CONNECTOR B365 i106
i107 21 20 1 2 3 4 B55 TCM
* *1 *2
AT-04892
5AT(diag)-27

Step CHECK AT OIL TEMP LIGHT. Turn the ignition switch to ON. CHECK AT OIL TEMP LIGHT. After the ignition switch is ON, wait for at least 2 seconds. CHECK AT OIL TEMP LIGHT. Start the engine. Check Does the AT OIL TEMP light illuminate? Does the AT OIL TEMP light illuminate? Yes Go to step 2. No Perform the selfdiagnosis of combination meter. Go to step 4.
Go to step 3.
Does the AT OIL TEMP light go Normal. Go back to off? Basic Diagnostic Procedure. <Ref. to 5AT(diag)-2, Basic Diagnostic Procedure.> CHECK SUBARU SELECT MONITOR COM- Is the communication between Go to step 5. MUNICATION. Subaru Select Monitor and Connect the Subaru Select Monitor to data link TCM normal? connector.
Go to step 7.
CHECK TCM. Display the current data of TCM using Subaru Select Monitor.
Is the Diagnosis Light output signal ON?
CHECK BODY INTEGRATED UNIT. Does the AT OIL TEMP light Display the current data of body integrated unit input signal Illuminate? using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.>
CHECK TCM. 1) Start the engine. 2) Display the current data of TCM using Subaru Select Monitor. <Ref. to 5AT(diag)-18, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Display the current data of body integrated unit using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.>
Is the Diagnosis Light output signal ON?
Does the AT OIL TEMP light input signal Illuminate?
Check the power supply ground circuit of TCM and Subaru Select Monitor communication. <Ref. to 5AT(diag)-29, Diagnostic Procedure for Subaru Select Monitor Communication.> Go to step 6. Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> Replace the com- Check DTC of body integrated bination meter assembly. <Ref. to unit. <Ref. to IDI-22, Combina- LAN(diag)-12, OPERATION, Subtion Meter.> aru Select Monitor.> Replace the TCM. Go to step 8. <Ref. to 5AT-60, Transmission Control Module (TCM).> Perform the selfCheck DTC of diagnosis of combody integrated bination meter. unit. Perform the diagnosis accord- <Ref. to IDI-5, ing to DTC. <Ref. INSPECTION, Combination Meter to LAN(diag)-12, OPERATION, Sub- System.> aru Select Monitor.>
5AT(diag)-28


DIAGNOSIS: Defective harness connector TROUBLE SYMPTOM: Subaru Select Monitor communication failure WIRING DIAGRAM:
B40
BATTERY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
MAIN SBF
No. 13 16 IG2 RELAY SBF-8 No. 4 8
E
B55
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
M/B No. 12
SBF-6
7 5 4
DATA LINK CONNECTOR
B40
IGNITION SWITCH
A: B134 1 2 8 9 10 18 19 20 28 29 30 3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34
F/B No. 12
C6
A: B134 ECM C: B136 A5
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35 18 25 26 27 19 8
36
B55
TCM
B21 E2
23
22
B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48 35 43 49 36 50 37 44 51 38 45 52 39 53 40 46 54 41 47
AT-04893
5AT(diag)-29

Step Check CHECK SUBARU SELECT MONITOR POW- Is the voltage 10 V or more? ER SUPPLY CIRCUIT. Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 16 (+) Chassis ground (): CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. Measure the resistance of harness between data link connector and chassis ground. Connector & terminal (B40) No. 4 Chassis ground: (B40) No. 5 Chassis ground: CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to the transmission system can be executed normally. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM connector. 3) Turn the ignition switch to ON. 4) Check whether communication to engine system can be executed normally. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Connect the TCM connector. 3) Disconnect the connector from ECM. 4) Turn the ignition switch to ON. 5) Check whether communication to transmission system can be executed normally. CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and ECM connector. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B40) No. 7 Chassis ground: CHECK OUTPUT SIGNAL OF TCM. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM and chassis ground. Connector & terminal (B40) No. 7 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND DATA LINK CONNECTOR. Measure the resistance between TCM connector and data link connector. Connector & terminal (B55) No. 8 (B40) No. 7: CHECK INSTALLATION OF TCM CONNECTOR. Turn the ignition switch to OFF. Yes Go to step 2. No Repair harness connector between the battery and data link connector, and poor contact of the connector. Repair the open circuit of harness between data link connector and ground terminal, and poor contact of connector. Go to step 4.
Go to step 5.
Is the name of system disInspect the ECM. played on Subaru Select Monitor?
Go to step 6.
Go to step 7.
Check harness and connector between each control module and data link connector.
Check harness Go to step 8. and connector between each control module and data link connector. Is the resistance less than 1 :? Go to step 9. Repair the harness and connector between TCM and data link connector. Is TCM connector connected to Go to step 10. TCM? Connect the TCM connector to TCM.
5AT(diag)-30

Step Check CHECK INSTALLATION OF TRANSMISSION Is the transmission harness HARNESS CONNECTOR. connector connected to bulkhead harness connector? Yes Go to step 11. No Connect the bulkhead harness connector to transmission harness connector. Go to step 12.
10
11
12
13
14
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control module power supply and data link connector? CHECK POWER SUPPLY OF TCM. Is the voltage 10 13 V? 1) Disconnect the connector from TCM. 2) Turn the ignition switch to ON. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 24 (+) Chassis ground (): (B55) No. 25 (+) Chassis ground (): (B55) No. 26 (+) Chassis ground (): CHECK FUSE (NO. 12). Is the fuse (No. 12) blown out? 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 12). CHECK HARNESS. Is the resistance 10 : or less? Measure the resistance between TCM connector and chassis ground. Connector & terminal (B55) No. 24 Chassis ground: (B55) No. 25 Chassis ground: (B55) No. 26 Chassis ground:
Repair the poor contact. Go to step 15.
Go to step 13.
Replace the fuse (No. 12).
Go to step 14.
15
16
17
18
CHECK IGNITION POWER SUPPLY CIRIs the voltage 10 13 V? CUIT. 1) Turn the ignition switch to ON (engine OFF). 2) Measure the ignition power supply voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 17 (+) Chassis ground (): CHECK FUSE (NO. 21). Is the fuse (No. 21) blown out? Replace the fuse Remove the fuse (No. 21). (No. 21). If the replaced fuse (No. 21) has blown out easily, repair short circuit of harness between fuse (No. 21) and TCM. CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Repair the short TCM AND TRANSMISSION. more? circuit of harness 1) Turn the ignition switch to OFF. between TCM and 2) Disconnect the connector from TCM. transmission har3) Measure the resistance of the harness ness connector, between TCM and transmission ground. and poor contact of Connector & terminal connector. (B55) No. 22 Transmission ground: (B55) No. 23 Transmission ground: CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM Repair the connecpower supply, ground and data tor. link connector?
Replace the fuse Go to step 15. (No. 12). If the replaced fuse (No. 12) has blown out easily, repair short circuit of harness between fuse (No. 12) and TCM. Go to step 17. Go to step 16.
Go to step 17.
Go to step 18.
5AT(diag)-31


A: LIST
DTC P0705 Item Transmission Range Sensor Circuit (PRNDL Input) Transmission Fluid Temperature Sensor Circuit Low Input Transmission Fluid Temperature Sensor Circuit High Input Input/Turbine Speed Sensor Circuit Contents of diagnosis Inhibitor switch malfunction, open or short circuit Reference <Ref. to 5AT(diag)-35, DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-39, DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-41, DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-43, DTC P0715 INPUT/ TURBINE SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-46, DTC P0719 BRAKE SWITCH CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-48, DTC P0720 OUTPUT SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-51, DTC P0724 BRAKE SWITCH CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-53, DTC P0731 GEAR 1 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-53, DTC P0732 GEAR 2 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-53, DTC P0733 GEAR 3 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-53, DTC P0734 GEAR 4 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-53, DTC P0735 GEAR 5 INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-54, DTC P0736 REVERSE INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-55, DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-57, DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0712
ATF temperature sensor 1 malfunction, or open input signal circuit ATF temperature sensor 1 malfunction, short input signal circuit
P0713
P0715
Turbine speed sensor 1 malfunction, short input signal circuit
P0719
P0720
P0724
P0731
P0732
P0733
Brake Switch Circuit Low Brake switch malfunction, open input signal circuit, body integrated unit malfunction, CAN communication failure Output Speed Sensor Front wheel speed sensor is Circuit faulty or input signal circuit, ground, power supply is open or shorted. Brake Switch Circuit Brake switch malfunction, short High circuit of input signal, body integrated unit, CAN communication failure Gear 1 Incorrect Ratio Vehicle sensor, turbine speed sensor, control valve malfunction or shift clutch malfunction Gear 2 Incorrect Ratio Vehicle sensor, turbine speed sensor, control valve malfunction or shift clutch malfunction Gear 3 Incorrect Ratio Vehicle sensor, turbine speed sensor or shift clutch malfunction Gear 4 Incorrect Ratio Vehicle sensor, turbine speed sensor or shift clutch malfunction Vehicle sensor, turbine speed sensor or shift clutch malfunction Vehicle sensor, turbine speed sensor or shift clutch malfunction Lock-up clutch is faulty or valve is stuck.
P0734
P0735
Gear 5 Incorrect Ratio
P0736
Reverse Incorrect Ratio
P0741
Torque Converter Clutch Circuit Performance or Stuck Off Torque Converter Clutch Circuit Electrical
P0743
L/U solenoid circuit malfunction or L/U solenoid body malfunction
5AT(diag)-32

DTC P0748 Item Pressure Control Solenoid A Electrical Reference <Ref. to 5AT(diag)-59, DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Shift Solenoid A Perfor- Fr/B Solenoid Function Malfunc<Ref. to 5AT(diag)-61, DTC P0751 SHIFT mance or Stuck Off tion SOLENOID A PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Shift Solenoid A ElecFr/B solenoid circuit malfunction <Ref. to 5AT(diag)-63, DTC P0753 SHIFT trical or Fr/B solenoid body malfunction SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Shift Solenoid B Perfor- Shift Solenoid B Performance <Ref. to 5AT(diag)-65, DTC P0756 SHIFT mance or Stuck Off malfunction SOLENOID B PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Shift Solenoid B ElecI/C solenoid circuit malfunction or <Ref. to 5AT(diag)-67, DTC P0758 SHIFT trical I/C solenoid body malfunction SOLENOID B ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Shift Solenoid C Perfor- H&LR/C solenoid malfunction <Ref. to 5AT(diag)-69, DTC P0761 SHIFT mance or Stuck Off SOLENOID C PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Shift Solenoid C ElecH&LR/C solenoid circuit malfunc- <Ref. to 5AT(diag)-71, DTC P0763 SHIFT trical tion or H&LR/C solenoid body SOLENOID C ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> malfunction Shift Solenoid D Perfor- D/C solenoid malfunction mance or Stuck Off <Ref. to 5AT(diag)-73, DTC P0766 SHIFT SOLENOID D PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-75, DTC P0768 SHIFT SOLENOID D ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-77, DTC P0771 SHIFT SOLENOID E PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-79, DTC P0773 SHIFT SOLENOID E ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-81, DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-83, DTC P0817 STARTER DISABLE CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Contents of diagnosis Line pressure solenoid circuit malfunction or line pressure solenoid body malfunction
P0751
P0753
P0756
P0758
P0761
P0763
P0766
P0768
Shift Solenoid D Electrical
D/C solenoid circuit malfunction or D/C solenoid body malfunction
P0771
Shift Solenoid E Perfor- Fwd/B solenoid malfunction mance or Stuck Off
P0773
Shift Solenoid E Electrical Reverse Inhibit Control Circuit
P0801
P0817
Starter Disable Circuit
Fwd/B solenoid circuit malfunction or Fwd/B solenoid body malfunction Shift lock solenoid is faulty or output signal circuit is open or shorted. Blown out of TCM+B fuse PN signal output circuit is open or shorted. ECM Source Voltage Is Abnormal Blown out of TCM+B fuse Back-up relay output circuit is open, shorted or relay OFF malfunction Back-up relay output circuit is open, shorted or relay ON malfunction Rear wheel speed sensor is faulty or input circuit, ground, power supply is open or shorted.
P0957
Backup Light Relay Circuit Low Backup Light Relay Circuit High AT Vehicle Speed Sensor Circuit Malfunction (Rear Wheel)
P0958
P1706
<Ref. to 5AT(diag)-85, DTC P0957 BACKUP LIGHT RELAY CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-87, DTC P0958 BACKUP LIGHT RELAY CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-89, DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
5AT(diag)-33

DTC P1707 Item AT AWD Solenoid Valve Circuit Malfunction Contents of diagnosis AWD solenoid circuit malfunction or AWD solenoid body malfunction Torque converter sensor 2 malfunction, input circuit, ground, power open, short circuit CAN communication line bus-off open circuit, ECM short circuit, ABS/VDCCM or integrated CM malfunction Faulty lateral G sensor Reference <Ref. to 5AT(diag)-91, DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-93, DTC P1710 TORQUE CONVERTER TURBINE 2 SPEED SIGNAL CIRCUIT 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-95, DTC P1718 AT CAN COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-96, DTC P1760 LATERAL ACCELERATION SENSOR PERFORMANCE PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-98, DTC P1761 LATERAL ACCELERATION SENSOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-100, DTC P1762 LATERAL ACCELERATION SENSOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-103, DTC P1817 SPORT MODE SWITCH CIRCUIT (MANUAL SWITCH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-105, DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR/ SWITCH A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-105, DTC P1841 TRANSMISSION FLUID PRESSURE SENSOR/ SWITCH B CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-105, DTC P1842 TRANSMISSION FLUID PRESSURE SENSOR/ SWITCH C CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-105, DTC P1843 TRANSMISSION FLUID PRESSURE SENSOR/ SWITCH D CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to 5AT(diag)-105, DTC P1844 TRANSMISSION FLUID PRESSURE SENSOR/ SWITCH E CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1710
Torque Converter Turbine 2 Speed Signal Circuit 2 Malfunction AT CAN Communication Circuit
P1718
P1760
Lateral Acceleration Sensor Performance Problem Lateral Acceleration Sensor Circuit Low
P1761
Lateral G sensor is faulty, input signal circuit is open, or CAN communication failure occurs Lateral G sensor is faulty or input signal circuit is shorted.
P1762
Lateral Acceleration Sensor Circuit High
P1817
SPORT Mode Switch Circuit (Manual Switch)
Manual mode switch is open, shorted, or switch malfunction
P1840
Transmission Fluid Pressure Sensor/Switch A Circuit Transmission Fluid Pressure Sensor/Switch B Circuit Transmission Fluid Pressure Sensor/Switch C Circuit Transmission Fluid Pressure Sensor/Switch D Circuit Transmission Fluid Pressure Sensor/Switch E Circuit
Fr/B oil pressure switch is open or shorted, or switch malfunction
P1841
Fwd/B oil pressure switch is open or shorted, or switch malfunction
P1842
I/C oil pressure switch is open or shorted, or switch malfunction.
P1843
D/C oil pressure switch is open or shorted, or switch malfunction.
P1844
H&LR/C oil pressure switch is open or shorted, or switch malfunction.
5AT(diag)-34


A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
DTC DETECTING CONDITION: The inhibitor switch is open or short. TROUBLE SYMPTOM: Shift characteristics are erroneous. Shift indicator light does not match with select lever. Shift indicator light does not illuminate. N-D, N-R shock occur.
5AT(diag)-35

WIRING DIAGRAM:
i106 3 i107
No. 5
I/F
DRIVE CIRCUIT
LCD FULL DOT
1 2 3 4 COMBINATION METER i10 T14 B12 1 2 3 4 5 6 7 8
MICRO COMPUTER IGNITION SWITCH

21
22
SBF-6
WN WN
1 2 3 4 5 6
MAIN SBF
ON
ON
i10
CAN JOINT CONNECTOR
CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
BATTERY
i106
ON ON
i107
A:
WN WN
i84
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
A27
A26
E
A:
i84
B: B280 B20
B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
*2
*1
B30
CAN JOINT CONNECTOR
*1
*2
B365
B365
B21
A:
B54 A8
B: A9
B20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B55 A10 A11
TCM
A:
B54 5 6 14 15 16 25 26 27 33 34 35
B12 3 4 2 1 T3
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
T14 2 3 5 6 T24
B:
B55
* *1 *2
INHIBITOR SWITCH
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CONTROL VALVE BODY
AT-04894
5AT(diag)-36

Step CHECK DTC OF TCM. Check Yes No Is DTC of AT CAN communica- Perform the diag- Go to step 2. tion circuit displayed? nosis according to DTC. Is all displayed High? Go to step 4. Go to step 3.
CHECK INHIBITOR SWITCH. 1) Shift the select lever to P range. 2) Check input signal of inhibitor SW 1 4 monitor using Subaru Select Monitor. CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance between TCM connector and chassis ground about the item which indicated Low on step 2. Connector & terminal (B54) No. 8 Chassis ground: (B54) No. 9 Chassis ground: (B54) No. 10 Chassis ground: (B54) No. 11 Chassis ground: CHECK INHIBITOR SWITCH. 1) Shift the select lever to D range. 2) Check input signal of inhibitor SW 1 4 monitor using Subaru Select Monitor. CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector about the item which indicated High on step 4. Connector & terminal (B54) No. 8 (B12) No. 4: (B54) No. 9 (B12) No. 3: (B54) No. 10 (B12) No. 2: (B54) No. 11 (B12) No. 1: CHECK INPUT SIGNAL FOR TCM USING CIRCUIT TESTER. 1) Turn the ignition switch to OFF. 2) Disconnect the transmission connector (B12). 3) Connect the TCM connector. 4) Turn the ignition switch to ON. 5) Measure the voltage between TCM terminals. Connector & terminal (B54) No. 8 (+) (B55) No. 23 (): (B54) No. 9 (+) (B55) No. 23 (): (B54) No. 10 (+) (B55) No. 23 (): (B54) No. 11 (+) (B55) No. 23 (): CHECK TCM I/O SIGNAL. Check the power supply and ground I/O signals. <Ref. to 5AT(diag)-14, ELECTRICAL SPECIFICATION, Transmission Control Module (TCM) I/ O Signal.>
Go to step 6.
Repair the short circuit of harness between TCM connector and chassis ground.
Is all displayed Low?
Go to step 6.
Go to step 5.
Repair the open circuit of harness between TCM connector and transmission connector.
Is the voltage of inhibitor SW 1 Go to step 8. 4 between 4 6 V?
Go to step 7.
Is TCM I/O signal OK?
Repair the open or short circuit for power supply and ground.
5AT(diag)-37

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the connector from control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T3) No. 4 (T14) No. 2: (T3) No. 3 (T14) No. 3: (T3) No. 2 (T14) No. 5: (T3) No. 1 (T14) No. 6: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T14) No. 2 Transmission ground: (T14) No. 3 Transmission ground: (T14) No. 5 Transmission ground: (T14) No. 6 Transmission ground: CHECK POOR CONTACT. Check Yes Is the resistance less than 1 :? Go to step 9. No Repair the open circuit of harness between control valve body connector and transmission connector.
Go to step 10.
Repair the short circuit of harness between control valve body connector and transmission connector.
10
Is there any poor contact in Repair the poor inhibitor SW 1 4 monitor cir- contact. cuit?
5AT(diag)-38

B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Input signal circuit to ATF temperature sensor is open. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
B54 TCM
T10 1 2 3 4 5 6 7 8 9 10
17 18
B11 B11 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
5 12
T10 3 4 T20 B54

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
CONTROL VALVE BODY
AT-04348
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 17 (B11) No. 5: (B54) No. 18 (B11) No. 12: CHECK ATF OIL TEMPERATURE SENSOR. Is the resistance 300 800 :? Go to step 3. 1) Turn the ignition switch to OFF. 2) Connect the connectors to transmission and TCM. 3) Turn the ignition switch to ON and start engine. 4) Warm up the transmission until the ATF temperature exceeds 80C (176F). NOTE: If the ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Disconnect the connector from transmission. 6) Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 (T4) No. 12:
Go to step 5.
5AT(diag)-39

Step CHECK ATF OIL TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 (T4) No. 12: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect the connector. 2) Turn the ignition switch to ON. (engine OFF) 3) Read the ATF temperature using Subaru Select Monitor. Check Yes Does the resistance value Go to step 4. increase while the ATF temperature decreases? No Go to step 5.
Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness between ATF oil temperature sensor and transmission connector. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Replace the conTRANSMISSION AND CONTROL VALVE trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the connector from control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 12 (T10) No. 4: (T4) No. 5 (T10) No. 3: CHECK POOR CONTACT. Is there poor contact in ATF oil Repair the poor temperature sensor circuit? contact.
Go to step 6.
Repair the open circuit of harness between transmission connector and control valve body connector.
5AT(diag)-40

C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Input signal circuit to ATF oil temperature sensor is shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
B54 TCM
T10 1 2 3 4 5 6 7 8 9 10
17 18
B11 B11 T4
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
5 12
T10 3 4 T20 B54

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
CONTROL VALVE BODY
AT-04348
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 2. TCM AND TRANSMISSION. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 17 Chassis ground: (B54) No. 18 Chassis ground: CHECK ATF OIL TEMPERATURE SENSOR. Is the resistance 300 800 :? Go to step 3. 1) Turn the ignition switch to OFF. 2) Connect the connectors to transmission and TCM. 3) Turn the ignition switch to ON and start engine. 4) Warm up the transmission until the ATF temperature exceeds 80C (176F). NOTE: If the ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Disconnect the connector from transmission. 6) Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 (T4) No. 12:
No Repair the short circuit of harness between TCM and transmission connector.
Go to step 5.
5AT(diag)-41

Step CHECK ATF OIL TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 (T4) No. 12: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect the connector. 2) Turn the ignition switch to ON. (engine OFF) 3) Read the ATF temperature using Subaru Select Monitor. Check Yes Does the resistance value Go to step 4. increase while the ATF temperature decreases? No Go to step 5.
CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or TRANSMISSION AND CONTROL VALVE more? BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the connector from control valve body connector. 7) Measure the resistance between chassis ground and control valve body connector. Connector & terminal (T10) No. 3 Chassis ground: (T10) No. 4 Chassis ground: CHECK POOR CONTACT. Is there poor contact in ATF oil Repair the poor temperature sensor circuit? contact.
Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness between ATF oil temperature sensor and transmission connector. Replace the control valve body. <Ref. to 5AT-57, Control Valve Body.>
Go to step 6.
Repair the short circuit of harness between transmission connector and control valve body connector.
5AT(diag)-42

D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT

DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: Excessive shift shock Does not shift to 5th. WIRING DIAGRAM:
TCM
B54 AT1
1 2 3
B12
16 27
26
1 2 3 4 5 6 7 8
B11 B12
2 7
B11
T4
T3
3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5
1 3 2
1 2
B54 AT1
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
TURBINE SPEED SENSOR 1
AT-04349
5AT(diag)-43

Step CHECK TCM I/O SIGNAL. Check the power supply and ground I/O signals. <Ref. to 5AT(diag)-14, ELECTRICAL SPECIFICATION, Transmission Control Module (TCM) I/ O Signal.> CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 16 (B11) No. 2: (B54) No. 26 (B12) No. 7: (B54) No. 27 (B11) No. 7: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 16 Chassis ground: (B54) No. 26 Chassis ground: (B54) No. 27 Chassis ground: CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to the TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. (engine OFF) 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) Chassis ground (): CHECK INPUT CIRCUIT OF TCM TURBINE SPEED SENSOR. Measure the voltage between TCM connector terminals. Connector & terminal (B12) No. 7 (+) (B11) No. 2 (): CHECK HARNESS ASSEMBLY (TURBINE SPEED SENSOR GROUND). Check the installing condition of ground connecting harness of harness assembly (used for both of turbine speed sensor 1, rear vehicle speed sensor). Check Is TCM I/O signal OK? Yes Go to step 2. No Repair the open or short circuit for power supply and ground. Repair the open circuit of harness between TCM and transmission connector.
Is the resistance less than 1 M:? Go to step 4.
Go to step 5.
Go to step 6.
Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> When poor installation of ground occurs, install it securely. Replace the transmission assembly if the harness or terminal is damaged. <Ref. to 5AT-39, Automatic Transmission Assembly.>
Is the ground connecting har- Go to step 7. ness installed securely to the transmission body? Is there any serious damage in the harness and terminal?
5AT(diag)-44

Step CHECK HARNESS ASSEMBLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Disconnect the connector from turbine speed sensor 1. 4) Measure the resistance between transmission connector and turbine speed sensor 1 connector. Connector & terminal (T3) No. 7 (AT1) No. 2: (T4) No. 7 (AT1) No. 3: (T4) No. 2 (AT1) No. 1: (AT1) No. 1 Chassis ground: CHECK HARNESS ASSEMBLY. Measure the resistance between transmission connector and chassis ground. Connector & terminal (T3) No. 7 Chassis ground: (T4) No. 7 Chassis ground: (T4) No. 2 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Lift up the vehicle. NOTE: Raise all wheels off the floor. 3) Start the engine, and set the vehicle in 4th speed driving condition of manual mode. NOTE: Turbine speed sensor 1 signal can be measured only on 4th speed. 4) Read the current data of turbine speed sensor 1 using the Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> Check Yes Is the resistance less than 1 :? Go to step 8. No Repair the open circuit of harness between TCM and transmission connector, or poor contact of connector.
Go to step 9.
Does the value of the turbine speed sensor 1 change depending on the acceleration, deceleration and shifting range of the vehicle?
Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness between ATF temperature sensor and transmission connector.
Replace the turbine speed sensor 1. <Ref. to 5AT-56, Turbine Speed Sensor 1.>
5AT(diag)-45

E: DTC P0719 BRAKE SWITCH CIRCUIT LOW

DTC DETECTING CONDITION: Stop light switch malfunction, open input signal circuit TROUBLE SYMPTOM: Brake down control does not operate at S# mode. WIRING DIAGRAM:
B65
1 3
STOP LIGHT SWITCH
No.8
2 4
B65 SBF-2
B159 1 2 3 4 5 6 7 8 9
MAIN SBF
B55
BATTERY
B159
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
7.5A
FUSE (RELAY BLOCK)
B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B225
C23
C: B281 B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
B20
B30
C: B281
B365
*1
CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
*1
* *
B365 B225
*1 *
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2 ,3,11,12 AND 13 2 : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 8, 9, 10, 18, 19 AND 20
21
20
1 3 5 7
2 4 6 8
9 10 11 12 25 26 27 28
13 14 15 16 29 30 31 32
17 18 19 20 33 34 35 36
21 22 23 24 37 38 39 40
B55
TCM
RELAY BLOCK
AT-04350
5AT(diag)-46

Step 1 CHECK DTC. Check Is any of following DTC displayed? / AT CAN Communication Circuit / Output Speed Sensor Circuit / AT Vehicle Speed Sensor Circuit Malfunction (Rear Wheel) Is the fuse (7.5A) blown out? Yes No Perform the diag- Go to step 2. nosis according to DTC.
CHECK FUSE (RELAY BLOCK). Remove the fuse (7.5A) in the relay block.
CHECK BODY INTEGRATED UNIT. Is ON displayed? 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. (engine OFF) 4) Turn the Subaru Select Monitor switch to ON. 5) Depress the brake pedal. 6) Read the data of "Stop Light Switch" using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK TCM. Is ON displayed? Read the data of "Stop Light Switch" using Subaru Select Monitor. <Ref. to 5AT(diag)-18, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Disconnect the connector from body integrated unit. 2) Depress the brake pedal. 3) Measure the voltage between body integrated unit connector and chassis ground. Connector & terminal (B281) No. 23 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from stop light switch. 3) Measure the resistance of harness between body integrated unit and stop light switch. Connector & terminal (B281) No. 23 (B65) No. 3: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. Measure the resistance of harness between body integrated unit connector and stop light switch. Connector & terminal (B281) No. 23 Chassis ground: CHECK POOR CONTACT. Is the voltage 10 V or more?
Replace the fuse Go to step 3. (7.5A). If the replaced fuse (7.5A) has blown out easily, repair short circuit of harness between fuse (7.5A) and body integrated unit. Go to step 4. Go to step 5.
Repair the open circuit of harness between body integrated unit and stop light switch.
Go to step 8.
Repair the short circuit of harness between body integrated unit and stop light switch.
5AT(diag)-47

F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT

DTC DETECTING CONDITION: AT vehicle speed signal is abnormal. The harness connector between TCM and front vehicle speed sensor is shorted or open. TROUBLE SYMPTOM: Shifting quality malfunction Driving performance is poor. WIRING DIAGRAM:
B54 TCM T15 T14 T10 1 2 3 4 5 6 7 8 9 10
3 2 1
24 16 27
1 2 3 4 5 6
B11 1 2 7 T4
B11
T10
T14 CONTROL VALVE BODY T15
3 6 7 9 10 11 13 14 15 17 18 19 5
1 2
4 8 12 16 20
4 1
B54 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
FRONT VEHICLE SPEED SENSOR
1 3
AT-04414
5AT(diag)-48

Step CHECK TCM I/O SIGNAL. Check the power supply and ground I/O signals. <Ref. to 5AT(diag)-14, ELECTRICAL SPECIFICATION, Transmission Control Module (TCM) I/ O Signal.> CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 24 (B11) No. 1: (B54) No. 16 (B11) No. 2: (B54) No. 27 (B11) No. 7: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 24 Chassis ground: CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to the TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. (engine OFF) 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) Chassis ground (): CHECK INPUT CIRCUIT OF TCM TURBINE SPEED SENSOR. Measure the voltage variation between TCM connector terminals. Connector & terminal (B11) No. 1 (+) (B11) No. 2 (): CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Lift up the vehicle. NOTE: Raise all wheels off the floor. 3) Start the engine, and drive it. 4) Read the current data of front wheel speed using Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> Check Is TCM I/O signal OK? Yes Go to step 2. No Repair the open or short circuit for power supply and ground. Repair the open circuit of harness between TCM and transmission connector.
Repair the short circuit of harness between TCM and transmission connector. Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).>
Go to step 5.
Go to step 6.
Does the value of the front wheel speed change depending on the acceleration and deceleration of the vehicle?
Even if the AT OIL Go to step 7. TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness between ATF temperature sensor and transmission connector.
5AT(diag)-49

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the connector from control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 1 (T10) No. 2: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 2 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN CONTROL VALVE BODY AND FRONT VEHICLE SPEED SENSOR. 1) Disconnect the connector from front vehicle speed sensor. 2) Measure the resistance of harness between control valve body connector and vehicle speed sensor connector. Connector & terminal (T14) No. 4 (T15) No. 1: (T10) No. 2 (T15) No. 2: (T14) No. 1 (T15) No. 3: CHECK HARNESS CONNECTOR BETWEEN CONTROL VALVE BODY AND FRONT VEHICLE SPEED SENSOR. Measure the resistance of harness between control valve body connector and transmission ground. Connector & terminal (T10) No. 2 Transmission ground: Check Yes Is the resistance less than 1 :? Go to step 8. No Repair the open circuit of harness between control valve body connector and transmission connector.
Go to step 9.
Repair the short circuit of harness between transmission connector and transmission ground. Replace the control valve body. <Ref. to 5AT-57, Control Valve Body.>
10
Replace the front Replace the convehicle speed sen- trol valve body. sor. <Ref. to 5AT-57, Control Valve Body.>
5AT(diag)-50

G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH

DTC DETECTING CONDITION: Stop light switch malfunction, open input signal circuit TROUBLE SYMPTOM: Gear is not shifted down when climbing a hill. WIRING DIAGRAM:
B65
1 3
STOP LIGHT SWITCH
No.8
2 4
B65 SBF-2
B159 1 2 3 4 5 6 7 8 9
MAIN SBF
B55
BATTERY
B159
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
7.5A
FUSE (RELAY BLOCK)
B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B225
C23
C: B281 B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
B20
B30
C: B281
B365
*1
CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
*1
* *
B365 B225
*1 *
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2 ,3,11,12 AND 13 2 : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 8, 9, 10, 18, 19 AND 20
21
20
1 3 5 7
2 4 6 8
9 10 11 12 25 26 27 28
13 14 15 16 29 30 31 32
17 18 19 20 33 34 35 36
21 22 23 24 37 38 39 40
B55
TCM
RELAY BLOCK
AT-04350
5AT(diag)-51

Step 1 CHECK DTC. Check Is any of following DTC detected? / AT CAN Communication Circuit / Output Speed Sensor Circuit / AT Vehicle Speed Sensor Circuit Malfunction (Rear Wheel) Is OFF displayed? Yes No Perform the diag- Go to step 2. nosis according to DTC.
CHECK BODY INTEGRATED UNIT. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. (engine OFF) 4) Turn the Subaru Select Monitor switch to ON. 5) Read the data of "Stop Light Switch" using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK TCM. Is OFF displayed? Read the data of "Stop Light Switch" using Subaru Select Monitor. <Ref. to 5AT(diag)-18, OPERATION, Subaru Select Monitor.>
Go to step 3.
Go to step 4.
CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Disconnect the connector from body integrated unit. 2) Measure the voltage between body integrated unit connector and chassis ground. Connector & terminal (B281) No. 23 (+) Chassis ground (): CHECK STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from stop light switch. 3) Measure the resistance of harness between stop light switch connectors. Connector & terminal (B65) No. 3 (B65) No. 2: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. 1) Turn the ignition switch to ON. 2) Measure the voltage of harness between body integrated unit connector and chassis ground. Connector & terminal (B281) No. 23 (+) Chassis ground (): CHECK POOR CONTACT.
Go to step 6.
Replace the stop light switch.
Go to step 7.
Repair the short circuit of harness between TCM and stop light switch.
5AT(diag)-52

H: DTC P0731 GEAR 1 INCORRECT RATIO

I:
DTC P0732 GEAR 2 INCORRECT RATIO
J: DTC P0733 GEAR 3 INCORRECT RATIO

K: DTC P0734 GEAR 4 INCORRECT RATIO

L: DTC P0735 GEAR 5 INCORRECT RATIO

5AT(diag)-53

M: DTC P0736 REVERSE INCORRECT RATIO

DTC DETECTING CONDITION: Target gear ratio and actual gear ratio do not match. TROUBLE SYMPTOM: Shift point is too high or too low. Excessive shift shock Gear is not changed. The vehicle does not move in D or R range with the engine running at high speed.
1 Step CHECK DTC OF TCM. Check Is any DTC of the followings detected? P0715, P0720, P0753, P0758, P0763, P0768, P0773, P0751, P0756, P0761, P0766, P0771, P1706, P1710, P1718 Does the displayed value of the Subaru Select Monitor change according to engine speed and shifting? Yes No Perform the diag- Go to step 2. nosis according to DTC.
CHECK TURBINE SPEED SENSOR USING SUBARU SELECT MONITOR. 1) Lift up the vehicle. NOTE: Raise all wheels off the floor. 2) Start the engine, and drive it. 3) Read the current data of torque converter turbine speed using Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> CHECK FRONT AND REAR VEHICLE Do the values displayed for SPEED SENSORS. each of the Subaru Select Monitor and the speedometer substantially match? CHECK INHIBITOR SWITCH. Do the values displayed for the Subaru Select Monitor and the meter indicator match? DRIVING CHECK. Is DTC displayed again? 1) Turn the ignition switch to OFF. 2) After restarting the engine, check that the AT OIL TEMP light is not blinking, and perform a drive check based on the Inspection Mode. <Ref. to 5AT(diag)-22, PROCEDURE, Inspection Mode.> CHECK AFTER REPAIR. Is the trouble symptom unrepairable (malfunction in shifting such as excessive shift shock, engine speed increases excessively when shifting)?
Go to step 3.
Perform the diagnosis according to DTC P0715, P1710.
Go to step 4.
Go to step 5.
Check the DTC. Then, when proceeded again to step 5, go to step 6.
Perform the diagnosis according to DTC P0720, P1706. Perform the diagnosis according to DTC P0705. Go to step 6.
Replace the trans- Temporary poor mission assembly. contact occurs. Check that the harness connector is not faulty.
5AT(diag)-54

N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF

DTC DETECTING CONDITION: Defective lock-up clutch or torque converter assembly Defective control valve Defective turbine speed sensor 1 or 2 TROUBLE SYMPTOM: No lock-up occurs. (After engine is warmed up)
5AT(diag)-55

Step CHECK DTC OF TCM. Check Is any DTC of the followings detected? P0715, P0720, P0753, P0758, P0763, P0768, P0773, P0751, P0756, P0761, P0766, P0771, P1710, P1718 Are the engine speed and turbine speed almost the same? Yes No Perform the diag- Go to step 2. nosis according to each DTC.
DRIVING CHECK FOR LOCK-UP CONDITION. 1) Perform a drive check based on the Inspection Mode with the following conditions. <Ref. to 5AT(diag)-22, PROCEDURE, Inspection Mode.> (1) Read the current data of throttle opening angle using Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> (2) Keep the same vehicle speed at 60 km/h with 10% or less throttle opening angle which is read currently on Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> (3) Read the data of L/U Solenoid Pressure using Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> (4) Check the engine speed and turbine speed when the L/U solenoid target value displayed on Subaru Select Monitor is 500 kPa or more. DRIVING CHECK FOR LOCK-UP CONDIDoes the AT OIL TEMP light TION. blink and is DTC P0741 dis1) Clear the memory. <Ref. to 5AT(diag)-20, played? CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> 2) Perform a drive check based on the Inspection Mode with the following conditions. <Ref. to 5AT(diag)-22, PROCEDURE, Inspection Mode.> (1) Read the current data of throttle opening angle using Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> (2) Keep the same vehicle speed at 60 km/h with 10% or less throttle opening angle which is read currently on Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> (3) Read the data of L/U Solenoid Pressure using Subaru Select Monitor. <Ref. to 5AT(diag)-18, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> (4) Drive the vehicle continuously for one minute or more with the L/U solenoid target value displayed on Subaru Select Monitor at 500 kPa or more. 3) Turn the ignition switch to OFF. 4) Turn the ignition switch to ON. (Engine ON) 5) Perform the step 2) again.
Temporary poor Go to step 3. contact or open circuit occurs. Recheck that the harness connector has no faulty.
Replace the transmission assembly when DTC P0741 is displayed. When DTC other than P0741 is displayed, perform the diagnosis corresponding to the DTC.
Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.
5AT(diag)-56

O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of lock-up pressure linear solenoid is open or shorted. TROUBLE SYMPTOM: No lock-up occurs. (After engine is warmed up) WIRING DIAGRAM:
T11 A: B54 B: B55 TCM
1 2 3 4 5 6 7 8
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
B11
B23
B22
A7
A: 20 B11 T4
B54
5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T11 5
B55
LOCK-UP PRESSURE LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04352
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 7 (B11) No. 20: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 7 Chassis ground:
No Repair the open circuit of harness between TCM connector and transmission connector.
Repair the short circuit of harness between TCM connector and transmission connector.
5AT(diag)-57

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. NOTE: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 20 (T11) No. 5: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 5 Transmission ground: CHECK LOCK-UP PRESSURE LINEAR SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 5 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Repair the open circuit of harness between control valve body connector and transmission ground. Go to step 6.
Go to step 5.
Replace the control valve body. <Ref. to 5AT-57, Control Valve Body.> Go to step 7.
Is there any loosing terminal, Repair the poor entering foreign matter, damag- contact. ing connector body? Is DTC displayed? Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).>
5AT(diag)-58

P: DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of line pressure linear solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM:
T11 A: B54 B: B55 TCM
1 2 3 4 5 6 7 8
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
B11
B23
B22
A6
19
B11 T4
A:
B54
5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T11
B55
LINE PRESSURE LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04353
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 6 (B11) No. 19: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 6 Chassis ground:
5AT(diag)-59

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 19 (T11) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 1 Transmission ground: CHECK LINE PRESSURE LINEAR SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 1 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Go to step 5.
5AT(diag)-60

Q: DTC P0751 SHIFT SOLENOID A PERFORMANCE OR STUCK OFF

DTC DETECTING CONDITION: Output signal value of front brake linear solenoid does not match the oil pressure. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM:
A:
B54
B:
B55
TCM
T10 1 2 3 4 5 6 7 8 9 10
T11 1 2 3 4 5 6 7 8
B11
3 6 7 9 10 11 13 14 15 17 18 19 5
1 2
4 8 12 16 20
A15
B23
B22
A4
B11
17 3
A:
B54
5 6 14 15 16 25 26 27 33 34 35
T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
T10
T11
B:
B55
FRONT BRAKE OIL PRESSURE SWITCH
FRONT BRAKE LINEAR SOLENOID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CONTROL VALVE BODY
AT-04354
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 15 (B11) No. 3: (B54) No. 4 (B11) No. 17: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 4 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. (engine OFF) 3) Check input signal of F/B Fluid pressure.
Check Yes Is the resistance less than 1 :? Go to step 2.
Go to step 3.
Is OFF displayed?
Go to step 4.
5AT(diag)-61

Yes Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness in the solenoid output and oil pressure SW input. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Replace the conTRANSMISSION AND CONTROL VALVE trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (B11) No. 17 (T11) No. 8: (B11) No. 3 (T10) No. 7: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Replace the conTRANSMISSION AND CONTROL VALVE more? trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 7 Transmission ground: Step Check CHECK INPUT SIGNAL FOR TCM USING Is ON displayed? SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Turn the ignition switch to ON. (Engine ON) 3) Shift to 1st speed while checking the current gear position using Subaru Select Monitor. 4) Check input signal of F/B Fluid pressure. No Go to step 5.
Replace the transmission harness assembly.
5AT(diag)-62

R: DTC P0753 SHIFT SOLENOID A ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of front brake linear solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM:
T11 A: B54 B: B55 TCM
1 2 3 4 5 6 7 8
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
B11
B23
B22
A4
B11
17
A:
B54
5 6 14 15 16 25 26 27 33 34 35
T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
T11
B:
B55
FRONT BRAKE LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04355
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 4 (B11) No. 17: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 4 Chassis ground:
5AT(diag)-63

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 17 (T11) No. 8: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 8 Transmission ground: CHECK FRONT BRAKE LINEAR SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 8 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Repair the open circuit of harness between control valve body and transmission connector. Go to step 6.
Go to step 5.
5AT(diag)-64

S: DTC P0756 SHIFT SOLENOID B PERFORMANCE OR STUCK OFF

DTC DETECTING CONDITION: Output signal value of input clutch linear solenoid does not match the oil pressure. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM:
A: B54 B: B55 TCM
T10 1 2 3 4 5 6 7 8 9 10 T11 1 2 3 4 5 6 7 8 B11
3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5
1 2
A20
B23
B22
A3
B11
11 18
A:
B54
5 6 14 15 16 25 26 27 33 34 35
T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
T10
T11
B:
B55
INPUT CLUTCH OIL PRESSURE SWITCH
INPUT CLUTCH LINEAR SOLENOID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CONTROL VALVE BODY
AT-04356
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 3 (B11) No. 18: (B54) No. 20 (B11) No. 11: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 20 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. (engine OFF) 3) Check input signal of I/C Fluid Pressure.
Go to step 3.
Is OFF displayed?
Go to step 4.
5AT(diag)-65

Yes Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness in the solenoid output and oil pressure SW input. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Replace the conTRANSMISSION AND CONTROL VALVE trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 18 (T11) No. 3: (T4) No. 11 (T10) No. 8: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Replace the conTRANSMISSION AND CONTROL VALVE more? trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Check the insulation of transmission harness assembly. Connector & terminal (T10) No. 8 Transmission ground: Step Check CHECK INPUT SIGNAL FOR TCM USING Is ON displayed? SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Turn the ignition switch to ON. (Engine ON) 3) Drive the vehicle on 4th speed of D range with checking current gear position using Subaru Select Monitor. 4) Check input signal of I/C Fluid Pressure. No Go to step 5.
5AT(diag)-66

T: DTC P0758 SHIFT SOLENOID B ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of input clutch linear solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM:
T11 A: B54 B: B55 TCM
1 2 3 4 5 6 7 8
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
B11
B23
B22
A3
A: 18 B11 T4
B54
5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T11
B55
INPUT CLUTCH LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04357
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 3 (B11) No. 18: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND BODY HARNESS. more? Measure the resistance of harness between TCM connector and body harness. Connector & terminal (B54) No. 3 Chassis ground:
5AT(diag)-67

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 18 (T11) No. 3: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 3 Transmission ground: CHECK INPUT CLUTCH LINEAR SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 3 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Go to step 5. Repair the open circuit of harness between transmission connector and control valve body connector. Go to step 6. Replace the control valve body. <Ref. to 5AT-57, Control Valve Body.> Go to step 7.
5AT(diag)-68

U: DTC P0761 SHIFT SOLENOID C PERFORMANCE OR STUCK OFF

DTC DETECTING CONDITION: Output signal value of high & low reverse clutch linear solenoid does not match the oil pressure. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM:
T10 1 2 3 4 5 6 7 8 9 10 T11 1 2 3 4 5 6 7 8 B11
A:
B54
B:
B55
TCM
3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5
1 2
A14
B23
B22
A5
A: B11
15 4
B54
5 6 14 15 16 25 26 27 33 34 35
T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
T10
T11
B:
B55
HIGH & LOW REVERSE CLUTCH OIL PRESSURE SWITCH
HIGH & LOW REVERSE CLUTCH LINEAR SOLENOID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CONTROL VALVE BODY
AT-04358
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 5 (B11) No. 15: (B54) No. 14 (B11) No. 4: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 14 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. (engine OFF) 3) Check the input signal of the H&LR/C Fluid Pressure.
Go to step 3.
Is OFF displayed?
Go to step 4.
5AT(diag)-69

Yes Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness in the solenoid output and oil pressure SW input. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Replace the conTRANSMISSION AND CONTROL VALVE trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 15 (T11) No. 2: (T4) No. 4 (T10) No. 6: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Replace the conTRANSMISSION AND CONTROL VALVE more? trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Check the insulation of transmission harness assembly. Connector & terminal (T10) No. 6 Transmission ground: Step Check CHECK INPUT SIGNAL FOR TCM USING Is ON displayed? SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Start the engine. 3) Drive the vehicle on 1st speed of manual mode 15 km/h (9 MPH) with checking current gear position using Subaru Select Monitor. 4) Read the data of "H&LR/C Fluid Pressure". No Go to step 5.
5AT(diag)-70

V: DTC P0763 SHIFT SOLENOID C ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of high & low reverse clutch linear solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM:
T11 A: B54 B: B55 TCM
1 2 3 4 5 6 7 8
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
B11
B23
B22
A5
A: B11
15
B54
5 6 14 15 16 25 26 27 33 34 35
T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T11
B55
HIGH & LOW REVERSE CLUTCH LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04359
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 5 (B11) No. 15: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 5 Chassis ground:
5AT(diag)-71

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 15 (T11) No. 2: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance of harness connector between control valve body connector and transmission ground. Connector & terminal (T11) No. 2 Transmission ground: CHECK HIGH & LOW REVERSE CLUTCH LINEAR SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 2 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Repair the open circuit of harness between control valve body connector and transmission ground.
Go to step 5.
Go to step 6.
Repair the poor Is there any loosing terminal, entering foreign matter, damag- contact. ing connector body? Is DTC displayed? Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).>
5AT(diag)-72

W: DTC P0766 SHIFT SOLENOID D PERFORMANCE OR STUCK OFF

DTC DETECTING CONDITION: Output signal value of direct clutch linear solenoid does not match the oil pressure. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM:
T10 1 2 3 4 5 6 7 8 9 10 T11 1 2 3 4 5 6 7 8 B11
A:
B54
B:
B55
TCM
3 6 7 9 10 11 13 14 15 17 18 19 5
1 2
4 8 12 16 20
A22
B23
B22
A1
A: B11
16 10
B54
5 6 14 15 16 25 26 27 33 34 35
T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T10 T11
9
B55
DIRECT CLUTCH OIL PRESSURE SWITCH
DIRECT CLUTCH LINEAR SOLENOID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CONTROL VALVE BODY
AT-04360
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 1 (B11) No. 16: (B54) No. 22 (B11) No. 10: CHECK HARNESS CONNECTOR BETWEEN TCM AND BODY HARNESS. Measure the resistance of harness between TCM connector and body harness. Connector & terminal (B54) No. 22 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. (engine OFF) 3) Check input signal of D/C oil pressure SW.
Go to step 3.
Is OFF displayed?
Go to step 4.
5AT(diag)-73

Yes Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness in the solenoid output and oil pressure SW input. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Replace the conTRANSMISSION AND CONTROL VALVE trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 16 (T11) No. 4: (T4) No. 10 (T10) No. 9: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Replace the conTRANSMISSION AND CONTROL VALVE more? trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Check the insulation of transmission harness assembly. Connector & terminal (T10) No. 9 Transmission ground: Step Check CHECK INPUT SIGNAL FOR TCM USING Is ON displayed? SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Turn the ignition switch to ON. (Engine ON) 3) Shift to 2nd speed of manual mode and brake ON with checking current gear position using Subaru Select Monitor. 4) Check input signal of D/C oil pressure SW. No Go to step 5.
5AT(diag)-74

X: DTC P0768 SHIFT SOLENOID D ELECTRICAL

DTC DETECTING CONDITION: The output signal circuit of direct clutch linear solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM:
T11 A: B54 B: B55 TCM
1 2 3 4 5 6 7 8
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
B11
B23
B22
A1
A: 16 B11 T4
B54
5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T11 4
B55
DIRECT CLUTCH LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04361
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 1 (B11) No. 16: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 1 Chassis ground:
5AT(diag)-75

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 16 (T11) No. 4: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 4 Transmission ground: CHECK DIRECT CLUTCH LINEAR SOLENOID. Measure the resistance of harness connector between control valve body connector and transmission ground. Connector & terminal (T11) No. 4 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Go to step 5.
Go to step 7.
5AT(diag)-76

Y: DTC P0771 SHIFT SOLENOID E PERFORMANCE OR STUCK OFF

DTC DETECTING CONDITION: Output signal of forward brake linear solenoid does not match the oil pressure. TROUBLE SYMPTOM: Locked to 2nd, 3rd, 4th gear. WIRING DIAGRAM:
T10 1 2 3 4 5 6 7 8 9 10 T11 1 2 3 4 5 6 7 8 B11
A:
B54
B:
B55
TCM
3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5
1 2
A21
A19
B23
B22
A: B11
13 9
B54
5 6 14 15 16 25 26 27 33 34 35
T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T10
10
B55
T11
FORWARD BRAKE OIL PRESSURE SWITCH
FORWARD BRAKE LINEAR SOLENOID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
CONTROL VALVE BODY
AT-04362
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 19 (B11) No. 13: (B54) No. 21 (B11) No. 9: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 21 Chassis ground: CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. (engine OFF) 3) Check input signal of Fwd/B hydraulic pressure SW.
Go to step 3.
Is OFF displayed?
Go to step 4.
5AT(diag)-77

Yes Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness in the solenoid output and oil pressure SW input. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Replace the conTRANSMISSION AND CONTROL VALVE trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 13 (T11) No. 7: (T4) No. 9 (T10) No. 10: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Replace the conTRANSMISSION AND CONTROL VALVE more? trol valve body. BODY. <Ref. to 5AT-57, 1) Turn the ignition switch to OFF. Control Valve 2) Disconnect the connector from transmisBody.> sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Check the insulation of transmission harness assembly. Connector & terminal (T10) No. 10 Transmission ground: Step Check CHECK INPUT SIGNAL FOR TCM USING Is ON displayed? SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Turn the ignition switch to ON. (Engine ON) 3) Drive the vehicle on 2nd speed of manual mode 15 km/h (9 MPH) with checking current gear position using Subaru Select Monitor. 4) Check input signal of Fwd/B hydraulic pressure SW. No Go to step 5.
Repair the short circuit of harness between transmission connector and control valve body connector.
5AT(diag)-78

Z: DTC P0773 SHIFT SOLENOID E ELECTRICAL

DTC DETECTING CONDITION: Output signal circuit of forward brake linear solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 2nd, 3rd, 4th gear. WIRING DIAGRAM:
T11 A: B54 B: B55 TCM
1 2 3 4 5 6 7 8
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
B11
A19
B23
B22
A: 13 B11 T4
B54
5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
B: T11
B55
FORWARD BRAKE LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04363
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: (B54) No. 19 (B11) No. 13: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND BODY HARNESS. more? Measure the resistance of harness between TCM connector and body harness. Connector & terminal (B54) No. 19 Chassis ground:
5AT(diag)-79

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 13 (T11) No. 7: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 7 Transmission ground: CHECK FORWARD BRAKE LINEAR SOLENOID. Measure the resistance of harness connector between control valve body connector and transmission ground. Connector & terminal (T11) No. 7 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Go to step 5.
Go to step 7.
Temporary poor contact occurs. Recheck that the harness connector has no faulty.
5AT(diag)-80

AA:DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

DTC DETECTING CONDITION: Shift lock solenoid malfunction, open or short reverse inhibitor control circuit TROUBLE SYMPTOM: Gear is shifted from N range to R range during driving at 20 km/h (12 MPH) or more. Gear can not be shifted from N range to R range though the vehicle is parked. WIRING DIAGRAM:
B280
B116
3 4 5 1 2 6 7 8 9 10 11 12
SHIFT LOCK SOLENOID

B116
B280
3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 27 28 29 30 21 22
E
AT-04340
Step CHECK SHIFT LOCK SOLENOID. 1) Start the integrated unit by force, and check the operation of shift lock solenoid. <Ref. to LAN(diag)-12, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.> 2) Operate AT select lever without depressing the brake pedal. CHECK OUTPUT SIGNAL OF INTEGRATED UNIT. 1) Display the following items using Subaru Select Monitor. Key-lock warning SW Shift Position P SW Stop Light Switch 2) Step on the brake and shift the AT select lever to P range. CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND SHIFT LOCK SOLENOID. Measure the harness resistance between the body integrated unit and chassis ground. Connector & terminal (B280) No. 6 Chassis ground:
Check Yes Does the AT select lever oper- Go to step 2. ate?
No Go to step 3.
Do the units of measure of items displayed change?
Go to step 3.
Check the circuits of the items whose values do not change.
Go to step 4.
Repair the short circuit of harness between body integrated unit and shift lock solenoid connector.
5AT(diag)-81

Step CHECK HARNESS BETWEEN SHIFT LOCK SOLENOID AND CHASSIS GROUND TERMINAL. Measure the resistance of harness between shift lock solenoid and chassis ground. Connector & terminal (B116) No. 4 Chassis ground: CHECK SHIFT LOCK SOLENOID. Measure the resistance of shift lock solenoid terminals. Connector & terminal (B116) No. 3 No. 4: CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) With the brake pedal depressed, shift the AT select lever to D range. 4) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B280) No. 6 (+) Chassis ground (): CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Lift up the vehicle. NOTE: Raise all wheels off the floor. 2) Start the engine. 3) Shift the AT select lever to D range and slowly increase vehicle speed to exceed 20 km/ h (12 MPH). NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B280) No. 6 (+) Chassis ground (): CHECK POOR CONTACT. Check Yes Is the resistance less than 1 :? Go to step 5. No Repair the open circuit of harness between chassis ground and shift lock solenoid connector. Replace the shift lock solenoid.
Go to step 6.
Go to step 8.
Even if the AT OIL Go to step 8. TEMP light illuminates, the circuit is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the harness or connector in the reverse inhibitor control circuit.
Is there poor contact in the Repair the poor reverse inhibitor control circuit? contact.
5AT(diag)-82

AB:DTC P0817 STARTER DISABLE CIRCUIT

DTC DETECTING CONDITION: Open or short in P/N signal output circuit TROUBLE SYMPTOM: Engine can be started on other than P or N range Engine can not be started on P or N range. WIRING DIAGRAM:
B136
ECM
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
31
B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 TCM 5 6 14 15 16 25 26 27 33 34 35
B55
11
AT-04364
5AT(diag)-83

Yes No Perform the diag- Go to step 2. nosis according to DTC. Go to step 3. Perform the diagCHECK ECM. nosis according to DTC concerning ECM. CHECK FUSE (NO. 32). Is the fuse (No. 32) blown out? Replace the fuse Go to step 4. 1) Turn the ignition switch to OFF. (No. 32). If the 2) Remove the fuse. replaced fuse (No. 32) has blown out easily, repair short circuit of harness between fuse (No. 32) and TCM. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 5. Repair the open TCM AND ECM. circuit of harness 1) Turn the ignition switch to OFF. between TCM and 2) Disconnect the connector from TCM and transmission contransmission. nector, or poor 3) Measure the resistance of harness between contact of connecTCM connector and transmission connector. tor. Connector & terminal (B55) No. 11 (B136) No. 31 CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 6. Repair the short TCM AND ECM. more? circuit of harness Measure the resistance of harness between between transmisTCM connector and chassis ground. sion connector and Connector & terminal chassis ground. (B55) No. 11 Chassis ground: CHECK TCM OUTPUT SIGNAL. Is the voltage 1 V or less? Go to step 7. Replace the TCM. 1) Connect the TCM and ECM connector. <Ref. to 5AT-60, 2) Turn the ignition switch to ON. (engine OFF) Transmission Con3) Shift the select lever to P range. trol Module 4) Measure the voltage between TCM connec(TCM).> tor and chassis ground. Connector & terminal (B55) No. 11 (+) Chassis ground (): CHECK TCM OUTPUT SIGNAL. Is the voltage 8 V or more? Go to step 8. Replace the TCM. 1) Shift the select lever to D range. <Ref. to 5AT-60, 2) Measure the voltage between TCM connecTransmission Contor and chassis ground. trol Module Connector & terminal (TCM).> (B55) No. 11 (+) Chassis ground (): CHECK POOR CONTACT. Is there any open or poor con- Repair the poor Check the neutral tact of connector (loosing termi- contact. switch of ECM. nal, entering foreign matter, damaging connector body)? Step CHECK DTC OF TCM. Check Is DTC of Transmission Range Sensor Circuit (PRNDL Input) detected? Is the communication between Subaru Select Monitor and ECM normal?
5AT(diag)-84

AC:DTC P0957 BACKUP LIGHT RELAY CIRCUIT LOW

DTC DETECTING CONDITION: Output circuit of the back-up light relay is open or shorted TROUBLE SYMPTOM: Back-up light does not illuminate in R range. WIRING DIAGRAM:
IG2 RELAY MAIN SBF SBF-8
No.18
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
BATTERY
B226
BACK-UP LIGHT RELAY
E
B226
1 2 3 4
7 8 9 10 5 11
6
4 2
BACK-UP LIGHT SYSTEM
13
B55
TCM
AT-04365
5AT(diag)-85

Check Is DTC of Transmission Range Sensor Circuit (PRNDL Input) detected? CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? TCM AND BACK-UP LIGHT RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM and back-up light relay. 3) Measure the resistance of harness between TCM connector and back-up light relay connector. Connector & terminal (B55) No. 13 (B226) No. 4: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or TCM AND TRANSMISSION. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 13 Chassis ground: CHECK TCM OUTPUT SIGNAL. Is the voltage 8 V or more? 1) Turn the ignition switch to ON. (engine OFF) 2) Shift the select lever to P range. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 13 (+) Chassis ground (): CHECK TCM OUTPUT SIGNAL. Is the voltage 1 V or less? 1) Set the select lever to R range. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 13 (+) Chassis ground (): CHECK INPUT VOLTAGE FOR BACK-UP Is the voltage 10 13 V? LIGHT RELAY. Measure the voltage between back-up light relay and chassis ground. Step CHECK DTC OF TCM. Yes No Perform the diag- Go to step 2. nosis according to DTC. Go to step 3. Repair the open circuit of harness between TCM and transmission connector, or poor contact of connector.
Go to step 4.
Go to step 5.
Go to step 6.
Replace the back- Check open or up light relay. short circuit of harness between fuse (No. 18) and backup light relay.
5AT(diag)-86

AD:DTC P0958 BACKUP LIGHT RELAY CIRCUIT HIGH

DTC DETECTING CONDITION: Output circuit of the back-up light relay is open or shorted TROUBLE SYMPTOM: Back-up light does not illuminate in R range. WIRING DIAGRAM:
IG2 RELAY MAIN SBF SBF-8
No.18
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
BATTERY
B226
BACK-UP LIGHT RELAY
E
B226
1 2 3 4
7 8 9 10 5 11
6
4 2
BACK-UP LIGHT SYSTEM
13
B55
TCM
AT-04365
5AT(diag)-87

Check Is DTC of Transmission Range Sensor Circuit (PRNDL Input) detected? CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? TCM AND BACK-UP LIGHT RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM and back-up light relay. 3) Measure the resistance of harness between TCM connector and back-up light relay connector. Connector & terminal (B55) No. 13 (B226) No. 4: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or TCM AND TRANSMISSION. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 13 Chassis ground: CHECK TCM OUTPUT SIGNAL. Is the voltage 8 V or more? 1) Turn the ignition switch to ON. (engine OFF) 2) Shift the select lever to P range. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 13 (+) Chassis ground (): CHECK TCM OUTPUT SIGNAL. Is the voltage 1 V or less? 1) Set the select lever to R range. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 13 (+) Chassis ground (): CHECK INPUT VOLTAGE FOR BACK-UP Is the voltage 10 13 V? LIGHT RELAY. Measure the voltage between back-up light relay and chassis ground. Step CHECK DTC OF TCM. Yes No Perform the diag- Go to step 2. nosis according to DTC. Go to step 3. Repair the open circuit of harness between TCM and transmission connector, or poor contact of connector.
Go to step 4.
Go to step 5.
Go to step 6.
Replace the back- Check open or up light relay. short circuit of harness between fuse (No. 18) and backup light relay.
5AT(diag)-88

AE:DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL)

DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: Shifting quality malfunction Tight corner braking phenomenon occurs. WIRING DIAGRAM:
TCM B54 1 2 3 16 27 23 AT4 B12 1 2 3 4 5 6 7 8
B11
B11 2 7 5 T4
B12 T3
3 6 7 9 10 11 13 14 15 17 18 19 5
1 2
4 8 12 16 20
B54 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
REAR VEHICLE SPEED SENSOR
1 3 2 AT4
AT-04366
Step CHECK TCM I/O SIGNAL. Check the power supply and ground I/O signals. <Ref. to 5AT(diag)-14, ELECTRICAL SPECIFICATION, Transmission Control Module (TCM) I/ O Signal.> CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 23 (B12) No. 5: (B54) No. 27 (B11) No. 7: (B54) No. 16 (B11) No. 2: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 23 Chassis ground: (B54) No. 27 Chassis ground: (B54) No. 16 Chassis ground:
Check Is TCM I/O signal OK?
Yes Go to step 2.
No Repair the open or short circuit for power supply and ground. Repair the open circuit of harness between TCM and transmission connector.
Go to step 4.
5AT(diag)-89

Step CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to the TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. (engine OFF) 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) Chassis ground (): CHECK INPUT CIRCUIT OF TCM TURBINE SPEED SENSOR. Measure the voltage variation between TCM connector terminals. Connector & terminal (B12) No. 5 (+) (B11) No. 2 (): CHECK HARNESS ASSEMBLY (TURBINE SPEED SENSOR GROUND). Check the installing condition of ground connecting harness (used for both of turbine speed sensor 1, rear vehicle speed sensor). Check Is the voltage 10 13 V? Yes Go to step 5. No Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).>
Go to step 7.
Go to step 6.
When the poor installation of ground connecting harness, install it securely. Replace the transmission assembly when the harness is damaged. <Ref. to 5AT-39, Automatic Transmission Assembly.> CHECK INPUT SIGNAL FOR TCM USING Does the value of the rear Even if the AT OIL Replace the transSUBARU SELECT MONITOR. wheel speed depending on the TEMP light blinks, mission harness. 1) Connect all connectors. acceleration and deceleration the system is in 2) Lift up the vehicle. of the vehicle? normal condition. A temporary poor NOTE: contact of connecRaise all wheels off the floor. tor or harness may 3) Start the engine, and drive the vehicle. be the cause. 4) Read the current data of rear wheel speed Repair poor conusing Subaru Select Monitor. <Ref. to tact of harness in 5AT(diag)-18, OPERATION, Subaru Select ATF temperature Monitor.> sensor and transNOTE: mission connector. The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.>
Is the ground connecting harness installed to transmission body correctly, or the harness and connector terminals not damaged?
Go to step 7.
5AT(diag)-90

AF:DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION

DTC DETECTING CONDITION: Output signal circuit of transfer linear solenoid is open or shorted. TROUBLE SYMPTOM: Tight corner braking phenomenon occurs. Drivability getting worse. WIRING DIAGRAM:
T11 B11
3 4 8 6 7 9 10 11 12 16 14 15 13 17 18 19 20 1 2 5
A:
B54
B:
B55
TCM
1 2 3 4 5 6 7 8
B23
B22
A2
B54 B11 8 T4
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B55
T11
TRANSFER LINEAR SOLENOID CONTROL VALVE BODY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
AT-04367
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 2 (B11) No. 8: (B55) No. 22 Chassis ground: (B55) No. 23 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 23 Chassis ground:
5AT(diag)-91

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 8 (T11) No. 6: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 6 Transmission ground: CHECK TRANSFER LINEAR SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 6 Transmission ground: CHECK POOR CONTACT. Check that there are no poor contact in TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while, read the DTC, and check that there is no faulty. Check Yes Is the resistance less than 1 :? Go to step 4. No Repair the open circuit of harness between transmission connector and control valve body connector.
Go to step 5.
5AT(diag)-92

AG:DTC P1710 TORQUE CONVERTER TURBINE 2 SPEED SIGNAL CIRCUIT 2 MALFUNCTION

DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: Excessive shift shock Does not shift to 5th. WIRING DIAGRAM:
T14 B54 TCM
1 2 3 4 5 6
25 T10 1 2 3 4 5 6 7 8 9 10 B12 1 2 3 4 5 6 7 8
16
27
B11
2 7 6
B12 T3
T4
B11
3 4 8 6 7 9 10 11 12 14 15 13 16 17 18 19 20 1 2 5
T14
T10
B54
TURBINE SPEED SENSOR 2
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32
5 6 14 15 16 25 26 27 33 34 35
CONTROL VALVE BODY
AT-04368
Step CHECK TCM I/O SIGNAL. Check the power supply and ground I/O signals. <Ref. to 5AT(diag)-14, ELECTRICAL SPECIFICATION, Transmission Control Module (TCM) I/ O Signal.> CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 25 (B12) No. 6: (B54) No. 16 (B11) No. 2: (B54) No. 27 (B11) No. 7: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 25 Chassis ground: CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to the TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. (engine OFF) 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) Chassis ground ():
Check Is TCM I/O signal OK?
Yes Go to step 2.
No Repair the open or short circuit for power supply and ground. Repair the open circuit of harness between TCM and transmission connector.
Go to step 5.
5AT(diag)-93

Step CHECK INPUT CIRCUIT OF TCM TURBINE SPEED SENSOR 2. Measure the voltage between TCM connector terminals. Connector & terminal (B12) No. 6 (+) (B11) No. 2 (): CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Lift up the vehicle. NOTE: Raise all wheels off the floor. 3) Start the engine, and set the vehicle in 1st speed driving condition of manual mode. 4) Read the current data of torque converter turbine speed 2 using Subaru Select Monitor. <Ref. to 5AT(diag)-18, OPERATION, Subaru Select Monitor.> NOTE: The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS or VDC clear memory of on-board diagnostics system. <Ref. to ABS(diag)-20, Clear Memory Mode.> <Ref. to VDC(diag)-23, Clear Memory Mode.> CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. NOTE: Raise all wheels off the floor. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan, and disconnect the connector from control valve body connector. 7) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T3) No. 6 (T10) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 1 Transmission ground: Check Is the voltage 4 6 V? Yes Go to step 6. No Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).>
Does the value of the turbine speed sensor 2 change depending on the acceleration, deceleration and shifting gear of the vehicle?
Even if the AT OIL Go to step 7. TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Repair the poor contact of harness of turbine speed sensor 2 and transmission connector.
Repair the open circuit of harness between transmission connector and control valve body connector.
Repair the short circuit of harness between transmission connector and transmission ground.
5AT(diag)-94

AH:DTC P1718 AT CAN COMMUNICATION CIRCUIT

NOTE: DTC P1718 AT CAN communication circuit, refer to LAN System. <Ref. to LAN(diag)-12, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.>
5AT(diag)-95

AI: DTC P1760 LATERAL ACCELERATION SENSOR PERFORMANCE PROBLEM

DTC DETECTING CONDITION: Lateral G sensor output voltage fault WIRING DIAGRAM:
B359 A: B54 A18 B: B55 B7 B9 TCM 1 2 3
A: B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B: B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B359
LATERAL G SENSOR
AT-04479
Step CHECK VEHICLE CONDITION.
CHECK DTC OF TCM.
CHECK DTC OF ABS.
Check Yes Is the vehicle a model with Go to step 2. VDC, which has the VDC OFF switch on the instrument panel? Is DTC of AT CAN communica- Perform the diagtion detected? nosis according to DTC. Is DTC of ABS detected? Perform the diagnosis according to DTC of ABS.
No Go to step 4.
Go to step 3.
CHECK OUTPUT OF LATERAL G SENSOR USING SUBARU SELECT MONITOR. Read the value of Lateral G Sensor using Subaru Select Monitor. CHECK OUTPUT OF LATERAL G SENSOR USING SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Remove the console box. 3) Remove the lateral G sensor from vehicle. (Do not disconnect the connector.) 4) Turn the ignition switch to ON. 5) Read the value of Lateral G Sensor using Subaru Select Monitor. CHECK OUTPUT OF LATERAL G SENSOR USING SUBARU SELECT MONITOR. Read the value of Lateral G Sensor using Subaru Select Monitor. CHECK POOR CONTACT IN CONNECTOR. Turn the ignition switch to OFF.
Is the reading indicated on monitor display 2.3 to 2.7 V?
Go to step 5.
Temporary poor contact occurs. Recheck for defective parts in harness and connectors. Go to step 10.
Is the value on the display 3.3 Go to step 6. 4.3 V with the lateral G sensor inclined 90 to right?
Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.>
Is the value on the display 0.7 Go to step 7. 1.7 V with the lateral G sensor inclined 90 to left?
Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.> Is there poor contact in connec- Repair the connec- Go to step 8. tor between TCM and lateral G tor. sensor?
5AT(diag)-96

Yes Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> Is any other DTC displayed? Perform the diagnosis according to DTC. CHECK OPEN CIRCUIT IN LATERAL G SEN- Is the resistance 5.0 6.0 k:? Go to step 11. SOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM. 3) Measure the resistance between TCM connector terminals. Connector & terminal (B54) No. 18 (B55) No. 7: CHECK LATERAL G SENSOR. Is the voltage 2.3 2.7 V when Go to step 12. 1) Remove the console box. lateral G sensor is in horizontal 2) Remove the lateral G sensor from vehicle. position? 3) Connect the connector to lateral G sensor. 4) Connect the connector to ABSCM&H/U. 5) Turn the ignition switch to ON. 6) Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK LATERAL G SENSOR. Is the voltage 3.3 4.3 V when Go to step 13. Measure the voltage between lateral G sensor lateral G sensor is inclined 90 connector terminals. to right? Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK LATERAL G SENSOR. Is the voltage 0.7 1.7 V when Go to step 14. Measure the voltage between lateral G sensor lateral G sensor is inclined 90 connector terminals. to left? Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK ABSCM&H/U. Is the same DTC displayed? Replace the TCM. 1) Turn the ignition switch to OFF. <Ref. to 5AT-60, 2) Connect all connectors. Transmission Con3) Perform the Clear Memory Mode. trol Module 4) Perform the Inspection Mode. (TCM).> 5) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diagnosis according to DTC. Step CHECK ABSCM&H/U. 1) Connect all connectors. 2) Perform the Clear Memory Mode. 3) Perform the Inspection Mode. 4) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the same DTC displayed? No Go to step 9.
Temporary poor contact occurs. Repair the harness between lateral G sensor and TCM.
10
11
12
Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.> Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.> Go to step 15.
13
14
15
Temporary poor contact occurs.
5AT(diag)-97

AJ:DTC P1761 LATERAL ACCELERATION SENSOR CIRCUIT LOW

DTC DETECTING CONDITION: Lateral G sensor open circuit or output voltage fault (Model without VDC) CAN communication malfunction (Model with VDC) WIRING DIAGRAM:
B359 A: B54 A18 B: B55 B7 B9 TCM 1 2 3
A: B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B: B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B359
LATERAL G SENSOR
AT-04479
Step CHECK VEHICLE CONDITION.
CHECK DTC OF TCM.
CHECK DTC OF ABS.
Check Yes Is the vehicle a model with Go to step 2. VDC, which has the VDC OFF switch on the instrument panel? Is DTC of AT CAN communica- Perform the diagtion detected? nosis according to DTC. Is DTC of ABS detected? Perform the diagnosis according to DTC of ABS.
No Go to step 4.
Go to step 3.
CHECK OUTPUT OF LATERAL G SENSOR USING SUBARU SELECT MONITOR. Read the value of Lateral G Sensor using Subaru Select Monitor. CHECK POOR CONTACT IN CONNECTOR. Turn the ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Perform the Clear Memory Mode. 3) Perform the Inspection Mode. 4) Read the DTC. CHECK OTHER DTC DETECTION.
Is the reading indicated on Go to step 5. monitor display 2.3 to 2.7 V when lateral G sensor is level? Is there poor contact in connec- Repair the connector between TCM and lateral G tor. sensor? Is the same DTC displayed? Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> Is any other DTC displayed? Perform the diagnosis according to DTC.
Go to step 6.
Go to step 7.
5AT(diag)-98

Step Check Yes CHECK OPEN CIRCUIT IN LATERAL G SEN- Is the resistance 5.0 6.0 k:? Go to step 9. SOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM. 3) Measure the resistance between TCM connector terminals. Connector & terminal (B54) No. 18 (B55) No. 7: CHECK GROUND SHORT OF HARNESS. Is the resistance 1 M: or Go to step 10. Measure the resistance between TCM connecmore? tor and chassis ground. Connector & terminal (B54) No. 18 Chassis ground: No Repair the harness between lateral G sensor and TCM.
10
11
12
13
14
CHECK LATERAL G SENSOR. 1) Remove the console box. 2) Remove the lateral G sensor from vehicle. 3) Connect the connector to lateral G sensor. 4) Connect the TCM connector. 5) Turn the ignition switch to ON. 6) Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK LATERAL G SENSOR. Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK LATERAL G SENSOR. Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK TCM. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Perform the Clear Memory Mode. 4) Perform the Inspection Mode. 5) Read the DTC. CHECK OTHER DTC DETECTION.
Is the voltage 2.3 2.7 V when Go to step 11. lateral G sensor is in horizontal position?
Repair the harness between lateral G sensor and TCM. Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.>
Is the voltage 3.3 4.3 V when Go to step 12. lateral G sensor is inclined 90 to right?
Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.> Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.>
Is the voltage 0.7 1.7 V when Go to step 13. lateral G sensor is inclined 90 to left?
Is the same DTC displayed?
Replace the TCM. Go to step 14. <Ref. to 5AT-60, Transmission Control Module (TCM).> Perform the diag- Temporary poor nosis according to contact occurs. DTC.
Is any other DTC displayed?
5AT(diag)-99

AK:DTC P1762 LATERAL ACCELERATION SENSOR CIRCUIT HIGH

DTC DETECTING CONDITION: Lateral G sensor output voltage fault WIRING DIAGRAM:
B359 A: B54 A18 B: B55 B7 B9 TCM 1 2 3
A: B54
1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
B: B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
B359
LATERAL G SENSOR
AT-04479
5AT(diag)-100

Step CHECK VEHICLE CONDITION. Check Yes Is the vehicle a model with Go to step 2. VDC, which has the VDC OFF switch on the instrument panel? Is DTC of AT CAN communica- Perform the diagtion detected? nosis according to DTC. Is DTC of ABS detected? Perform the diagnosis according to DTC of ABS. No Go to step 4.
CHECK DTC OF TCM.
Go to step 3.
CHECK DTC OF ABS.
10
11
12
Is there poor contact in connec- Repair the connector between TCM and lateral G tor. sensor? CHECK ABSCM&H/U. Is the same DTC displayed? Replace the TCM. 1) Connect all connectors. <Ref. to 5AT-60, 2) Perform the Clear Memory Mode. Transmission Con3) Perform the Inspection Mode. trol Module (TCM).> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diagnosis according to DTC. CHECK INFORMATION STORED IN FREEZE Is the reading on monitor 4.65 V Go to step 9. or more? FRAME DATA. Read the value of Lateral G Sensor using Subaru Select Monitor. CHECK OPEN CIRCUIT IN LATERAL G SEN- Is the resistance 4.3 4.9 k:? Go to step 10. SOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM. 3) Measure the resistance between TCM connector terminals. Connector & terminal (B55) No. 9 (B54) No. 18: CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 11. 1) Turn the ignition switch to OFF. 2) Remove the console box. 3) Disconnect the connector from the lateral G sensor. 4) Disconnect the connector from TCM. 5) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 7 (+) Chassis ground (): CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 12. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 7 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connec- Repair the connector between TCM and lateral G tor. sensor?
CHECK OUTPUT OF LATERAL G SENSOR USING SUBARU SELECT MONITOR. Read the value of Lateral G Sensor using Subaru Select Monitor. CHECK POOR CONTACT IN CONNECTOR.
Is the reading indicated on Go to step 5. monitor display 2.3 to 2.7 V when lateral G sensor is level?
Go to step 6.
Go to step 7.
Temporary poor contact occurs. Go to step 15.
Repair the harness connector between the lateral G sensor and ABSCM&H/U.
Repair the harness between lateral G sensor and TCM.
Go to step 13.
5AT(diag)-101

Step CHECK TCM. 1) Connect all connectors. 2) Perform the Clear Memory Mode. 3) Perform the Inspection Mode. 4) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the same DTC displayed? Yes Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> Perform the diagnosis according to DTC. Go to step 16. No Go to step 14.
13
14
Temporary poor contact occurs. Repair the harness between lateral G sensor and TCM.
15
16
17
18
19
20
CHECK LATERAL G SENSOR INPUT VOLTAGE. 1) Turn the ignition switch to OFF. 2) Remove the console box. 3) Remove the lateral G sensor from vehicle. (Do not disconnect the connector.)) 4) Turn the ignition switch to ON. 5) Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 1 (+) No. 2 (): CHECK OPEN CIRCUIT IN LATERAL G SENSOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM. 3) Measure the resistance between TCM connector terminals. Connector & terminal (B55) No. 9 No. 7: CHECK LATERAL G SENSOR. 1) Connect the connector to lateral G sensor. 2) Connect the TCM connector. 3) Turn the ignition switch to ON. 4) Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK LATERAL G SENSOR. Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK LATERAL G SENSOR. Measure the voltage between lateral G sensor connector terminals. Connector & terminal (B359) No. 3 (+) No. 2 (): CHECK POOR CONTACT IN CONNECTOR. Turn the ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Perform the Clear Memory Mode. 3) Perform the Inspection Mode. 4) Read the DTC. CHECK OTHER DTC DETECTION.
Is the resistance 5.0 5.6 k:? Go to step 17.
Is the voltage 2.3 2.7 V when Go to step 18. lateral G sensor is in horizontal position?
Is the voltage 3.3 4.3 V when Go to step 19. lateral G sensor is inclined 90 to right?
Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.> Replace the lateral G sensor. <Ref. to 5AT-61, Lateral G Sensor.> Go to step 21.
Is the voltage 0.7 1.7 V when Go to step 20. lateral G sensor is inclined 90 to left?
21
22
Is there poor contact in connec- Repair the connector between TCM and lateral G tor. sensor? Is the same DTC displayed? Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> Is any other DTC displayed? Perform the diagnosis according to DTC.
Go to step 22.
5AT(diag)-102

AL:DTC P1817 SPORT MODE SWITCH CIRCUIT (MANUAL SWITCH)

DTC DETECTING CONDITION: Input signal circuit of SPORT/manual mode switch is open or shorted. TROUBLE SYMPTOM: Manual mode can not be set. When shifting to N o D, the SPORT shift indicator light illuminates. WIRING DIAGRAM:
i10 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22 3
No. 5
LCD FULL DOT
LCD (AT / SPORT SHIFT) LCD DRIVER
COMBINATION METER
A:
i84
IGNITION SWITCH
DRIVE CIRCUIT
i10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
SBF-6
B: B280 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
MAIN SBF
WN WN
ON
ON
C: B281
BATTERY CAN JOINT CONNECTOR CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
i106
ON ON
* *
* *
i107
E
A27 A26
WN WN
B55
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
A:
i84
B: B280 C26
C: B281
B365 B20 B30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AT SELECT LEVER
*2
*1
CAN JOINT CONNECTOR
i106 i107 1 2 3 4
B116 8
*1
21
*2
20
B365
B116
* *1 *2
B55
TCM
3 4 5 1 2 6 7 8 9 10 11 12
AT-04895
5AT(diag)-103

Step CHECK BODY INTEGRATED UNIT. 1) Connect the Subaru Select Monitor to data link connector. 2) Turn the ignition switch to ON. (engine OFF) 3) Read the DTC of body integrated unit using Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Shift the AT select lever to P range. 2) Read the "Tiptronic Mode Switch" data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Shift the AT select lever from P to D range. 2) Read the "Tiptronic Mode Switch" data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Shift the AT select lever to manual mode. 2) Shift the AT select lever to other than D range. 3) Read the "Tiptronic Mode Switch" data of the body integrated unit using the Subaru Select Monitor. <Ref. to LAN(diag)-12, OPERATION, Subaru Select Monitor.> CHECK DTC OF TCM. Check Is DTC displayed? Yes No Perform the diag- Go to step 2. nosis according to DTC.
Is OFF displayed?
Go to step 3.
Go to step 7.
Is the indication on each range Go to step 4. OFF?
Is OFF displayed?
Go to step 5.
CHECK INPUT SIGNAL FROM TCM. 1) Shift the AT select lever from P to D range. 2) Read the "Tiptronic Mode Switch" data of the TCM using the Subaru Select Monitor. <Ref. to 5AT(diag)-18, OPERATION, Subaru Select Monitor.> CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND MANUAL MODE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect harness connector from body integrated unit and select lever. 3) Measure the harness resistance between the body integrated unit and chassis ground. Connector & terminal (B281) No. 27 Chassis ground:
Is DTC of Transmission Range Sensor Circuit (PRNDL Input) and AT CAN communication circuit displayed? Is the indication on each range OFF?
Perform the diag- Go to step 6. nosis according to each DTC. Even if the AT OIL TEMP light blinks, the system is in normal condition. A temporary poor contact of connector or harness may be the cause. Go to step 8. Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).>
Repair the short circuit of harness between body integrated unit and manual mode.
5AT(diag)-104

Step CHECK MANUAL MODE SWITCH. 1) Shift the select lever to P range. 2) Measure the resistance between harness connector terminals of SPORT/manual mode switch. Terminals (B116) No. 9 No. 8 Check Is the resistance 1 M: or more? Yes Check the body integrated unit. No Replace the select lever assembly. <Ref. to CS-23, Select Lever.>
AM:DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH A CIRCUIT

DTC DETECTING CONDITION: Front brake oil pressure switch malfunction TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0751 for diagnostic procedure. <Ref. to 5AT(diag)-61, DTC P0751 SHIFT SOLENOID A PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AN:DTC P1841 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH B CIRCUIT

DTC DETECTING CONDITION: Forward brake oil pressure switch malfunction TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0771 for diagnostic procedure. <Ref. to 5AT(diag)-77, DTC P0771 SHIFT SOLENOID E PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AO:DTC P1842 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH C CIRCUIT

DTC DETECTING CONDITION: Input clutch oil pressure switch is malfunction. TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0756 for diagnostic procedure. <Ref. to 5AT(diag)-65, DTC P0756 SHIFT SOLENOID B PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AP:DTC P1843 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH D CIRCUIT

DTC DETECTING CONDITION: Direct clutch oil pressure switch malfunction. TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0766 for diagnostic procedure. <Ref. to 5AT(diag)-73, DTC P0766 SHIFT SOLENOID D PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AQ:DTC P1844 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH E CIRCUIT

DTC DETECTING CONDITION: High & low reverse clutch oil pressure switch malfunction. TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0761 for diagnostic procedure. <Ref. to 5AT(diag)-69, DTC P0761 SHIFT SOLENOID C PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
5AT(diag)-105


A: CHECK MANUAL MODE SWITCH
DIAGNOSIS: Input signal circuit of SPORT/manual mode switch is open or shorted. TROUBLE SYMPTOM: Does not shift on manual mode. WIRING DIAGRAM:
B227
B116 3 4 5 1 2 6 7 8 9 10 11 12
1 2 3 C26 C15 C25
B20
B30
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
*1
*2
11
SPORT/ MANUAL MODESWITCH
*2
*1
B: B280 DOWN UP UP AT SELECT LEVER B116 DOWN PADDLE SHIFT SWITCH B227 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
21
20
10
B55
TCM
C: B281 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
*1 *2
B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31
AT-04370
Step Check CHECK BODY INTEGRATED UNIT. Is the ON/OFF normally 1) Perform ON/OFF operation on the SPORT/ detected? manual mode switch. 2) Read the data of Tiptronic Mode Switch using Subaru Select Monitor. CHECK DTC OF BODY INTEGRATED UNIT. Is DTC of CAN detected?
Yes Go to step 2.
No Go to step 7.
CHECK TCM. 1) Perform ON/OFF operation on the SPORT/ manual mode switch. 2) Read the data of Tiptronic Mode Switch using Subaru Select Monitor. CHECK SPORT SHIFT INDICATOR OF COMBINATION METER.
Is the ON/OFF normally detected?
Perform the diag- Go to step 3. nosis according to DTC. Go to step 4. Go to step 5.
Is the SPORT shift indicator light OK?
Go to step 6.
5AT(diag)-106

Yes No Perform the diag- Replace the TCM. nosis according to <Ref. to 5AT-60, DTC. Transmission Control Module (TCM).> CHECK DTC OF METER. Is DTC of CAN detected? Perform the diag- Replace the meter. nosis according to DTC. CHECK GROUND CIRCUIT OF SPORT/MAN- Is the resistance less than 1 :? Go to step 8. Repair the open UAL MODE SWITCH. circuit of harness 1) Turn the ignition switch to OFF. between SPORT/ 2) Disconnect the connector from SPORT/ manual mode manual mode switch. switch and chassis 3) Measure the resistance of harness between ground. SPORT/manual mode switch connector and chassis ground. Connector & terminal (B116) No. 6 Chassis ground: (B116) No. 10 Chassis ground: CHECK SPORT/MANUAL MODE SWITCH. Is the resistance 1 M: or Go to step 9. Replace the guide Measure the resistance between SPORT/man- more? plate assembly. ual mode switch terminals. Connector & terminal (B116) No. 6 No. 7: (B116) No. 10 No. 11: CHECK SPORT/MANUAL MODE SWITCH. Is the resistance less than 1 :? Go to step 10. Replace the guide 1) Move the select lever to manual mode. plate assembly. 2) Measure the resistance between SPORT/ manual mode switch terminals. Connector & terminal (B116) No. 6 No. 7: (B116) No. 10 No. 11: CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 :? Go to step 11. Repair the open BODY INTEGRATED UNIT AND SPORT/ circuit of harness MANUAL MODE SWITCH. between the 1) Disconnect the connector from body inteSPORT/manual grated unit. mode switch con2) Measure the resistance of harness between nector and body body integrated unit connector and SPORT/ integrated unit conmanual mode switch connector. nector, or poor Connector & terminal contact of connec(B116) No. 7 (B281) No. 15: tor. (B116) No. 11 (B281) No. 25: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 12. Repair the short BODY INTEGRATED UNIT AND SPORT/ more? circuit of harness MANUAL MODE SWITCH. between SPORT/ 1) Disconnect the connector from body intemanual mode grated unit. switch connector 2) Measure the resistance of harness between and body inteSPORT/manual mode switch connector and grated unit connecchassis ground. tor. Connector & terminal (B116) No. 7 Chassis ground: (B116) No. 9 Chassis ground: Step CHECK DTC OF TCM. Check Is DTC of CAN detected?
10
11
5AT(diag)-107

Step CHECK INPUT SIGNAL TO BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Turn the ignition switch to ON. (engine OFF) 3) Check the signal voltage for body integrated unit. Connector & terminal (B281) No. 15 (+) Chassis ground (): (B281) No. 25 (+) Chassis ground (): CHECK INPUT SIGNAL TO BODY INTEGRATED UNIT. 1) Shift and hold the AT select lever to shift up side. 2) Check the signal voltage for body integrated unit. Connector & terminal (B281) No. 15 (+) Chassis ground (): (B281) No. 25 (+) Chassis ground (): CHECK PADDLE SHIFT SWITCH GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from paddle shift switch. 3) Measure the resistance of harness between paddle shift switch connector and chassis ground. Connector & terminal (B227) No. 3 Chassis ground: CHECK PADDLE SHIFT SWITCH. Measure the resistance between paddle shift switch connector terminals. Connector & terminal (B227) No. 2 (B227) No. 3: Check Is the voltage 9 V or more? Yes Go to step 13. No Replace the body integrated unit. <Ref. to SL-56, Body Integrated Unit.>
12
13
Go to step 14.
14
Repair the open circuit of harness between paddle shift switch and chassis ground.
15
Go to step 16.
16
17
CHECK PADDLE SHIFT SWITCH. 1) Press and hold the + side of paddle shift switch. 2) Measure the resistance between paddle shift switch connector terminals. Connector & terminal (B227) No. 2 (B227) No. 3: CHECK POOR CONTACT.
Is there poor contact in the SPORT/manual mode switch circuit?
Replace the paddle shift switch connector or paddle shift switch. Or repair the poor contact of connector. Replace the paddle shift switch connector or paddle shift switch. Or repair the poor contact of connector. Temporary poor contact of the SPORT/manual mode switch circuit connector or harness.
5AT(diag)-108

B: CHECK SPORT SHIFT INDICATOR LIGHT

DIAGNOSIS: Output signal circuit of SPORT shift indicator light is open or shorted. TROUBLE SYMPTOM: SPORT shift indicator light does not illuminate or remains illuminated. SPORT shift indicator light display does not change. WIRING DIAGRAM:
i10 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22 3
No. 5
LCD FULL DOT
LCD (AT / SPORT SHIFT) LCD DRIVER
COMBINATION METER
A:
i84
IGNITION SWITCH
DRIVE CIRCUIT
i10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
SBF-6
B: B280 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
MAIN SBF
WN WN
ON
ON
C: B281
BATTERY CAN JOINT CONNECTOR CAN JOINT CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
i106
ON ON
* *
* *
i107
E
A27 A26
WN WN
B55
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
A:
i84
B: B280 C26
C: B281
B365 B20 B30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AT SELECT LEVER
*2
*1
CAN JOINT CONNECTOR
i106 i107 1 2 3 4
B116 8
*1
21
*2
20
B365
B116
* *1 *2
B55
TCM
3 4 5 1 2 6 7 8 9 10 11 12
AT-04895
5AT(diag)-109

Step CHECK BODY INTEGRATED UNIT. Check DTC of the body integrated unit. CHECK TCM. Check DTC of TCM. Check Yes Is DTC of AT CAN communica- Perform the diagtion circuit displayed? nosis according to DTC. Is DTC of AT CAN communica- Perform the diagtion circuit displayed? nosis according to DTC. Is the gear position at 1 and Go to step 4. displayed? No Go to step 2.
Go to step 3.
CHECK TCM. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. (engine OFF) 4) Turn the Subaru Select Monitor switch to ON. 5) Shift the AT select lever to manual mode side, and shift down the AT select lever. 6) Read the indicator. CHECK TCM. Is the gear position at 2 and 1) Shift up the AT select lever. displayed? 2) Read the indicator.
CHECK BODY INTEGRATED UNIT. Read the gear position data using Subaru Select Monitor.
Is the SPORT shift gear position 2?
CHECK COMBINATION METER.
Is the SPORT shift indicator OK?
Replace the TCM. <Ref. to 5AT-60, Transmission Control Module (TCM).> Go to step 6. Check the body integrated unit. <Ref. to SL-56, Body Integrated Unit.> Refer to SympReplace the comtom Related Diag- bination meter nostic. <Ref. to assembly. <Ref. to 5AT(diag)-113, IDI-22, CombinaGeneral Diagnos- tion Meter.> tic Table.>
Go to step 5.
5AT(diag)-110

C: CHECK BUZZER
DIAGNOSIS: Output signal circuit of buzzer is open or shorted. TROUBLE SYMPTOM: Buzzer remains beeping. WIRING DIAGRAM:
i10
No. 5
IGNITION SWITCH
BUZZER (SPORT SHIFT/ MULTI INDICATOR) MICRO COMPUTER DRIVE CIRCUIT
COMBINATION METER
6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
i10
A:
i84
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
WN WN
SBF-6
21
MAIN SBF
ON
ON
22
B: B280 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
BATTERY
CAN JOINT CONNECTOR
* *
* *
CAN JOINT CONNECTOR
i106
ON ON
i107
E
A27 A26
WN WN
B55
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35
A:
i84
B: B280
B20
B30
B365
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
*2 *2
*1 *1
CAN JOINT CONNECTOR
B365 i106
i107 21 20 1 2 3 4
* *1 *2
B55
TCM
AT-04896
5AT(diag)-111

Check Yes Is DTC of CAN communication Perform the diagdisplayed? nosis according to DTC. CHECK TCM. Is DTC of CAN communication Perform the diagCheck DTC of TCM. displayed? nosis according to DTC. CHECK BUZZER STOP. Does the buzzer stop? Replace the TCM. Disconnect the connector (B55). <Ref. to 5AT-60, Transmission Control Module (TCM).> CHECK BODY INTEGRATED UNIT. Is the SPORT shift buzzer dis- Replace the body 1) Turn the ignition switch to OFF. play ON? integrated unit. 2) Connect the Subaru Select Monitor to data <Ref. to SL-56, link connector. Body Integrated 3) Turn the ignition switch to ON. (engine OFF) Unit.> 4) Turn the Subaru Select Monitor switch to ON. 5) Read the data of SPORT shift buzzer using Subaru Select Monitor. CHECK COMBINATION METER. <Ref. to IDI- Is the buzzer OK? Refer to Symp5, SELF-DIAGNOSIS, INSPECTION, Combitom Related Diagnation Meter System.>. nostic. <Ref. to 5AT(diag)-113, General Diagnostic Table.> Step CHECK BODY INTEGRATED UNIT. Check DTC of the body integrated unit. No Go to step 2.
Go to step 3.
Go to step 4.
Go to step 5.
5AT(diag)-112


A: INSPECTION
Symptom Problem parts Vehicle speed sensor 1 and vehicle speed sensor 2 Accelerator pedal position sensor Throttle position sensor ATF temperature sensor CAN communication signal Vehicle speed sensor 1 and vehicle speed sensor 2 Accelerator pedal position sensor Throttle position sensor CAN communication signal Brake switch signal ATF temperature sensor Engine idle speed Engine speed signal Accelerator pedal position sensor Throttle position sensor Control cable adjustment ATF temperature sensor Oil pressure switch 1 and front brake solenoid valve CAN communication signal Fluid level and condition TCM power supply Accelerator pedal position sensor Throttle position sensor Control cable adjustment Oil pressure switch 4 and direct clutch solenoid valve CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition
Shifting vehicle speed is low on D range.
Shifting vehicle speed is high on D range.
Excessive shift shock(N o D range)
Excessive shift shock on 1st of D range o 2nd of D range or 1st of manual mode o 2nd of manual mode.
Excessive shift shock on 2nd of D range o 3rd of D range or 2nd of manual mode o 3rd of manual mode.
Excessive shift shock on 3rd of D range o 4th of D range or 3rd of manual mode o 4th of manual mode.
Accelerator pedal position sensor Throttle position sensor Control cable adjustment Oil pressure switch 5 and high & low reverse clutch solenoid valve CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment Oil pressure switch 3 and input clutch solenoid valve CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition
5AT(diag)-113

Symptom Problem parts Accelerator pedal position sensor Throttle position sensor Control cable adjustment Oil pressure switch 1 and front brake solenoid valve CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment Engine speed signal CAN communication signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment Engine speed signal CAN communication signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment CAN communication signal Fluid level and condition Line pressure Forward brake solenoid valve Fluid level and condition Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Accelerator pedal position sensor Throttle position sensor Lock up solenoid valve ATF temperature sensor Fluid level and condition Engine speed signal ATF temperature sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Direct clutch solenoid valve Line pressure Up switch signal CAN communication signal Accelerator pedal position sensor
Excessive shift shock on 4th of D range o 5th of D range or 4th of manual mode o 5th of manual mode.
Excessive shock at kick down.
Excessive shock at shift up.
Excessive shock at lock up.
Excessive shock at engine brake.
Judder is occurred at lock up.
Noise at R, N and D range.
Hold at D range or 1st on manual mode.
5AT(diag)-114

Symptom Problem parts Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Forward brake solenoid valve Line pressure Up switch signal Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Line pressure Up switch signal Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 3 and input clutch solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Oil pressure switch 5 and high & low reverse clutch solenoid valve Forward brake solenoid valve Front brake solenoid valve Line pressure Up switch signal Down switch signal CAN communication signal Accelerator pedal position sensor TCM power supply Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 1 and front brake solenoid valve Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 4 and direct clutch solenoid valve Line pressure Up switch CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 5 and high & low reverse clutch solenoid valve Line pressure Up switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 3 and input clutch solenoid valve Oil pressure switch 1 and front brake solenoid valve Line pressure Up switch signal CAN communication signal Accelerator pedal position sensor
Hold at D range or 2nd on manual mode.
Hold at D range or 3rd on manual mode.
Hold at D range or 4th on manual mode.
Hold at D range or 5th on manual mode.
Gear does not shift 1st of D range o 2nd of D range or 1st of manual mode o 2nd of manual mode.
Gear does not shift 2nd of D range o 3rd of D range or 2nd of manual mode o 3rd of manual mode.
Gear does not shift 3rd of D range o 4th of D range or 3rd of manual mode o 4th of manual mode.
5AT(diag)-115

Symptom Problem parts Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 1 and front brake solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Turbine speed sensor 1 and turbine speed sensor 2 ATF temperature sensor Line pressure Up switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 1 and front brake solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 3 and input clutch solenoid valve Oil pressure switch 1 and front brake solenoid valve Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor TCM power supply Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 5 and high & low reverse clutch solenoid Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 4 and direct clutch solenoid valve Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Line pressure Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve CAN communication signal ATF temperature sensor Accelerator pedal position sensor Brake switch signal Range signal Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 4 and direct clutch solenoid valve Line pressure CAN communication signal
Gear does not shift 4th of D range o 5th of D range or 4th of manual mode o 5th of manual mode.
Gear does not shift down to 4th on D range or manual mode.
Gear does not shift down to 3rd on D range or manual mode.
Gear does not shift down to 2nd on D range or manual mode.
Gear does not shift down to 1st on D range or manual mode.
No lock-up occurs.
No shift shock occurred when shifting 1st of D range o 2nd of D range or 1st of manual mode o 2nd of manual mode. Or clutch slipping occurred.
5AT(diag)-116

Symptom No shift shock occurred when shifting 2nd of D range o 3rd of D range or 2nd of manual mode o 3rd of manual mode. Or clutch slipping occurred. Problem parts Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 5 and high & low reverse clutch solenoid valve Line pressure CAN communication signal Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 3 and input clutch solenoid valve Oil pressure switch 1 and front brake solenoid valve Line pressure CAN communication signal Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 1 and front brake solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Line pressure Accelerator pedal position sensor Throttle position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 1 and front brake solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Line pressure Accelerator pedal position sensor Throttle position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 3 and input clutch solenoid valve Oil pressure switch 1 and front brake solenoid valve Line pressure Accelerator pedal position sensor Throttle position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 5 and high & low reverse clutch solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Line pressure Accelerator pedal position sensor Throttle position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 4 and direct clutch solenoid valve Line pressure Accelerator pedal position sensor Throttle position sensor Inhibitor switch Fluid level and condition Control cable adjustment Manual mode switch Oil pressure switch 1 Down switch signal Inhibitor switch Fluid level and condition Control cable adjustment Manual mode switch Oil pressure switch 1 and oil pressure switch 3 Down switch signal
No shift shock occurred when shifting 3rd of D range o 4th of D range or 3rd of manual mode o 4th of manual mode. Or clutch slipping occurred.
No shift shock occurred when shifting 4th of D range o 5th of D range or 4th of manual mode o 5th of manual mode. Or clutch slipping occurred.
Engine skids when shifting 5th of D range o 4th of D range or 5th of manual mode o 4th of manual mode. Or slipping occurred.
Engine skids when shifting 4th of D range o 3rd of D range or 4th of manual mode o 3rd of manual mode. Or slipping occurred.
Engine skids when shifting 3rd of D range o 2nd of D range or 3rd of manual mode o 2nd of manual mode. Or slipping occurred.
Engine skids when shifting 2nd of D range o 1st of D range or 2nd of manual mode o 1st of manual mode. Or slipping occurred.
Engine brake does not function at 5th o 4th of manual mode.
Engine brake does not function at 4th o 3rd of manual mode.
5AT(diag)-117

Symptom Problem parts Inhibitor switch Fluid level and condition Control cable adjustment Manual mode switch Oil pressure switch 5 Forward brake solenoid valve Inhibitor switch Fluid level and condition Control cable adjustment Manual mode switch Oil pressure switch 4 Forward brake solenoid valve Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Inhibitor switch Control cable adjustment Vehicle speed sensor 1, 2 Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor Oil pressure switch 5 and high & low reverse clutch solenoid valve CAN communication signal Inhibitor switch Control cable adjustment Vehicle speed sensor 1, 2 Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Oil pressure switch 4 and direct clutch solenoid valve Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Oil pressure switch 5 and high & low reverse clutch solenoid valve Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Oil pressure switch 3 and input clutch solenoid valve
Engine brake does not function at 3rd o 2nd of manual mode.
Engine brake does not function at 2nd o 1st of manual mode.
Excessive acceleration failure on D range.
Excessive acceleration failure in R range.
Engine skids when start driving (1st) the vehicle. Or slipping occurred.
Engine skids when driving at 2nd. Or slipping occurred.
Engine skids when driving at 3rd. Or slipping occurred.
Engine skids when driving at 4th. Or slipping occurred.
5AT(diag)-118

Symptom Problem parts Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Oil pressure switch 1 and front brake solenoid valve Fluid level and condition Line pressure Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve CAN communication signal Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Direct clutch solenoid valve Vehicle speed sensor 1 and 2 Fluid level and condition Engine speed signal CAN communication signal Oil pressure switch 4 and direct clutch solenoid valve Line pressure Engine speed signal CAN communication signal Oil pressure switch 4 Inhibitor switch Control cable adjustment Inhibitor switch Fluid level and condition Control cable adjustment Line pressure Inhibitor switch Fluid level and condition Control cable adjustment Line pressure Fluid level and condition Line pressure Inhibitor switch Control cable adjustment Loosing or damaging of propeller shaft. Loosing or damaging of drive shaft. Fluid level and condition Line pressure Inhibitor switch Control cable adjustment Loosing or damaging of propeller shaft. Loosing or damaging of drive shaft. Fluid level and condition Line pressure Inhibitor switch Control cable adjustment Loosing or damaging of propeller shaft. Loosing or damaging of drive shaft.
Engine skids when driving at 5th. Or slipping occurred.
Slip at lock up.
Maximum vehicle speed is low.
There is completely no creep.
Excessive large creep. Vehicle cannot be parking condition on P range. Parking condition is not released though shifting to other ranges. Vehicle can drive on P range.
Vehicle can drive on N range.
Vehicle cannot drive at any range.
Vehicle cannot drive on D range.
Vehicle cannot drive on R range.
5AT(diag)-119

Symptom Problem parts Push engine switch and starter Control cable adjustment Inhibitor switch CAN communication line TCM Push engine switch and starter Control cable adjustment Inhibitor switch TCM Fluid level and condition Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve Line pressure Fluid level and condition Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve Line pressure
Engine cannot start on N or P range
Engine start other than N or P range
Engine stalls.
Engine stalls when shifting to N o D and R range.
5AT(diag)-120
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Model Type 1st 2nd 3rd Transmission gear ratio 4th 5th Reverse Type of gear Front reduction gear Final Gear ratio Type of gear Transfer Gear ratio Rear reduction gear Type of gear Final Gear ratio Front differential Type and number of gear Center differential Type and number of gear Transmission gear oil Single-range Transmission gear oil capacity model 2.5 L non-turbo model 2.5 L turbo model Except for Except for OUTBACK OUTBACK OUTBACK OUTBACK 5-forward speeds and 1-reverse 3.454 3.166 2.062 1.882 1.448 1.296 1.088 0.972 0.780 0.825 0.738 3.333 Hypoid 3.900 4.111 3.900 4.444 Helical 1.000 Hypoid 3.900 4.111 3.900 4.444 Straight bevel gear (Bevel pinion: 2, Bevel gear: 2) Straight bevel gear (Bevel pinion: 2, bevel gear: 2 and viscous coupling) GL-5 3.5 2 (3.7 US qt, 3.1 Imp qt)
5MT-2
General Description
2. TRANSMISSION GEAR OIL

Recommended oil: GL-5 (75W-90) or equivalent
5. REVERSE IDLER GEAR

Adjustment of reverse idler gear position Reverse idler gear to transmission case (LH) wall clearance: 6.0 7.5 mm (0.236 0.295 in)
Part number 32820AA070 32820AA080 32820AA090 Reverse shifter lever Mark Remarks 7 Further from case wall 8 Standard 9 Closer to the case wall
3. TRANSMISSION CASE ASSEMBLY

Drive pinion shim adjustment Hypoid gear backlash: 0.13 0.18 mm (0.0051 0.0071 in)
Part number 32295AA031 32295AA041 32295AA051 32295AA061 Drive pinion shim Thickness Part number mm (in) 0.150 32295AA071 (0.0059) 0.175 32295AA081 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 32295AA091 32295AA101 Thickness mm (in) 0.250 (0.0098) 0.275 (0.0108) 0.300 (0.0118) 0.500 (0.0197)
After installing a suitable reverse shifter lever, adjust the clearance using washers. Reverse idler gear to transmission case wall clearance: 0 0.5 mm (0 0.020 in)
Part number 803020151 803020152 803020153 Washer (20.5 26 t) Thickness Part number mm (in) 0.4 (0.016) 1.1 (0.043) 1.5 (0.059) 803020154 803020155 Thickness mm (in) 1.9 (0.075) 2.3 (0.091)
Selection of main shaft rear plate

Main shaft rear plate Dimension A mm (in) Part number 4.00 4.13 32294AA041 (0.1575 0.1626) 3.87 4.00 32294AA051 (0.1524 0.1575) Mark 1 2
4. DRIVE PINION ASSEMBLY

Preload adjustment of thrust bearing Starting torque: 0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ft-lb)
Adjusting washer No. 1 Part number Thickness mm (in) 803025051 3.925 (0.1545) 803025052 3.950 (0.1555) 803025053 3.975 (0.1565) 803025054 4.000 (0.1575) 803025055 4.025 (0.1585) 803025056 4.050 (0.1594) 803025057 4.075 (0.1604) Adjusting washer No. 2 Part number Thickness mm (in) 803025059 3.850 (0.1516) 803025054 4.000 (0.1575) 803025058 4.150 (0.1634)
5MT-3
General Description
6. SHIFTER FORK AND ROD

Select a suitable shifter fork so that both the coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms. Rod end clearance: A: 3rd-4th 5th 0.5 1.3 mm (0.020 0.051 in) B: 1st-2nd 3rd-4th 0.4 1.4 mm (0.016 0.055 in)
Part number 32804AA060 32804AA070 32804AA080 1st-2nd shifter fork Mark Remarks Approaches 1st gear 1 by 0.2 mm (0.008 in). No mark Standard Approaches 2nd gear 3 by 0.2 mm (0.008 in). 3rd-4th shifter fork Mark Remarks Approaches 4th gear 1 by 0.2 mm (0.008 in). No mark Standard Approaches 3rd gear 3 by 0.2 mm (0.008 in). 5th shifter fork Mark 7 No mark 9
7. TRANSFER CASE
Neutral position adjustment
Part number 32190AA000 32190AA010 Adjusting shim Thickness mm (in) 0.15 (0.0059) 0.30 (0.0118)
Part number 32188AA130 32188AA140 32188AA150
Reverse accent shaft Mark Remarks Neutral position is S closer to 1st. T Standard Neutral position is U closer to reverse gear.
Reverse check plate adjustment

Part number 32189AA001 32189AA011 33189AA021 32189AA031 Reverse check plate Mark AngleT Remarks Arm stops closer to 0 28 5th gear. Arm stops closer to 1 31 5th gear. 2 3 4 34 37 40 Arm stops in the center. Arm stops closer to reverse gear. Arm stops closer to reverse gear.
Remarks Approaches 5th gear by 0.2 mm (0.008 in). Standard Moves away from 5th gear by 0.2 mm (0.008 in).
32189AA041
5MT-4
General Description
8. EXTENSION ASSEMBLY
Preload of the taper roller bearing (amount of standard protrusion): 0.15 0.25 mm (0.006 0.010 in) NOTE: Be sure that the amount of preload is within the standard value.
Thrust washer (50 61 t) Part number Thickness mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217) 803050062 0.60 (0.0236) 803050063 0.65 (0.0256) 803050064 0.70 (0.0276) 803050065 0.75 (0.0295) 803050066 0.80 (0.0315) 803050067 0.85 (0.0335) 803050068 0.90 (0.0354) 803050069 0.95 (0.0374) 803050070 1.00 (0.0394) 803050071 1.05 (0.0413) 803050072 1.10 (0.0433) 803050073 1.15 (0.0453) 803050074 1.20 (0.0472) 803050075 1.25 (0.0492) 803050076 1.30 (0.0512) 803050077 1.35 (0.0531) 803050078 1.40 (0.0551) 803050079 1.45 (0.0571)
9. FRONT DIFFERENTIAL
Bevel gear to pinion backlash: 0.13 0.18 mm (0.0051 0.0071 in)
Part number Washer (38.1 50 t) Thickness Part number mm (in) 0.925 0.950 (0.0364 0.0374) 0.975 1.000 (0.0384 0.0394) 803038023 Thickness mm (in) 1.025 1.050 (0.0404 0.0413)
803038021
803038022
10.TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance: 0.01 0.15 mm (0.0004 0.0059 in)
Snap ring (Outer-30) Part number Thickness mm (in) 805030041 1.53 (0.0602) 805030042 1.65 (0.0650) 805030043 1.77 (0.0697)
Thrust washer to center differential side clearance: 0.15 0.35 mm (0.0059 0.0138 in)
Part number 803036050 803036054 803036051 803036055 803036052 803036056 803036053 803036057 803036058 803036080 803036081 Thrust washer Thickness mm (in) 0.9 (0.035) 1.0 (0.039) 1.1 (0.043) 1.2 (0.047) 1.3 (0.051) 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) 1.7 (0.067) 1.8 (0.071) 1.9 (0.075)
5MT-5
General Description
B: COMPONENT
1. TRANSMISSION CASE
(9) (8)
(7) (6)
(11)
T2
(10) (5)
(4)
(1) (2) (3) T1
MT-01403
(1) (2) (3) (4) (5)
Transmission case assembly Gasket Drain plug Harness bracket (Non-turbo model) Harness bracket (Turbo model)
(6) (7) (8) (9) (10) (11)
Clamp Pitching stopper bracket Oil level gauge (Non-turbo model) Oil level gauge (Turbo model) Gasket Plug
Tightening torque:Nm (kgf-m, ft-lb) T1: 44 (4.5, 32.5) (Aluminum gasket) 70 (7.1, 51.6) (Copper gasket) T2: 60 (6.1, 44.3)
5MT-6
General Description
Transmission case tightening torque

Bolt No.
(9) (13) (1) (15) (14) (2) (4) (10) (6) (8) (12) MT-00003 (5) (7) (16) (17) (11) (3)
(5) (15)
Bolt size mm 8
Tightening torque: Nm (kgf-m, ft-lb) 25 (2.5, 18.4)
(1) (4) (16), (17)
10
39 (4.0, 28.8)
5MT-7
General Description
2. DRIVE PINION ASSEMBLY

(4) (5) (3) (2)
(1)
(17) (16) (11) (8) (7) (14) (13) (12) (10) (9) (6) (27) (28) T3 (36) (35) (15) (37)
(26) T1 (25) (24) (23) (22) (34) (32) (31) (29) (30) (33) T2
(21) (20) (19) (18) (29)
MT-01631
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Drive pinion shaft Roller bearing Washer Thrust bearing Needle bearing Driven shaft Key Woodruff key Drive pinion collar Needle bearing Snap ring (outer) (2.5 L non-turbo model) Washer (2.5 L non-turbo model) Sub gear (2.5 L non-turbo model) 1st driven gear
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
1st-2nd synchronizer hub Ball detent Reverse driven gear Outer baulk ring Synchro cone Inner baulk ring 2nd driven gear 2nd driven gear bushing 3rd-4th driven gear Driven pinion shim Roller bearing 5th driven gear Lock washer Lock nut
(29) (30) (31) (32) (33) (34) (35) (36) (37)
Adjusting washer Thrust bearing Differential bevel gear sleeve Adjusting washer Lock washer Lock nut Inner baulk ring Synchro cone Outer baulk ring
5MT-8
General Description
3. MAIN SHAFT FOR SINGLE-RANGE
(3)
(1)
(2) (14)
(17) (16) (15) (13) (11) (10) (9) (8) (7) (6) (12)
(5) (4)
(18)
(29) (28) (27)
(26) (25) (24) (23) (22) (19) (20) (21)
(34) (33) (32) (31) (30) MT-01572
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Oil seal Needle bearing Transmission main shaft Needle bearing 3rd drive gear Inner baulk ring 3rd synchro cone Outer baulk ring 3rd-4th coupling sleeve 3rd-4th synchronizer hub 3rd-4th shifting insert key 4th baulk ring 4th drive gear 4th needle bearing race
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Needle bearing 4th gear thrust washer Ball bearing (Non-turbo model) Taper roller bearing (Turbo model) 5th needle bearing race (Turbo model) 5th gear thrust washer (Non-turbo model) 5th needle bearing race (Nonturbo model) Needle bearing Main shaft rear plate 5th drive gear
(25) (26) (27) (28) (29) (30) (31) (32) (33) (34)
5th baulk ring Baulk lever 5th hub & sleeve No. 2 Lock washer Lock nut Straight pin Reverse idler gear shaft Washer Reverse idler gear Washer
5MT-9
General Description
4. SHIFTER FORK AND SHIFTER ROD

(1) (2)
(8) (7) (6) (5) T (3) (12) (18) (9) (10) (4)
(10) (7) (17) (16) (10) (3) (15) (14) (3) (13) MT-00007 (6) (5) T
(8) (11) (6) (5) T
(8) (7)
(1) (2) (3) (4) (5) (6) (7)
Shifter arm 5th shifter fork Straight pin Reverse fork rod Checking ball plug Gasket Checking ball spring
(8) (9) (10) (11) (12) (13) (14)
Ball 3rd-4th fork rod Interlock plunger 1st-2nd fork rod 3rd-4th shifter fork 1st-2nd shifter fork Ball
(15) (16) (17) (18)
Spring Snap ring (Outer) Reverse fork rod arm Reverse shifter lever
5MT-10
General Description
5. TRANSFER CASE AND EXTENSION

T3 (2) (20) (4) (5) (3) (6) (8) (1) T3 (7) T2
T1
(21) (23) T5
T5
(22) (12) (9) (10) (11) (15) (13) (16)
(14) (17) (19) T1 (18) (34) T6 (26) (27) (35) (36) T3
(25) (24) (31) (30) (29) (28) T4 (32) (37) (33) T6
MT-01562
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)
Oil guide Gasket Transfer case Ball Reverse accent spring Gasket Plug Oil seal Snap ring (Inner) Reverse check plate Reverse check spring Reverse return spring Reverse check cam Reverse accent shaft Return spring cap
(16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)
Return spring O-ring Adjusting select shim Reverse check sleeve Gasket Neutral position switch Gasket Back-up light switch Roller bearing Transfer driven gear Roller bearing Adjusting washer Ball bearing Center differential Adjusting washer
(31) (32) (33) (34) (35) (36) (37)
Transfer drive gear Ball bearing Extension Case Oil seal Dust cover Shift bracket Snap ring
Tightening torque:Nm (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 9.75 (1.0, 7.2) T3: 24.5 (2.5, 18.1) T4: 26 (2.7, 19.2) T5: 32.3 (3.3, 23.8) T6: 40 (4.1, 29.5)
5MT-11
General Description
6. FRONT DIFFERENTIAL
(5)
(7) (6)
(1) (6) (5) (8) (2) (3) (7)
(4) T2 (8) (11 ) (10) (12) (9) (12) (10)
(11 )
(13) T1
T1
(13) MT-01778
(1) (2) (3) (4) (5) (6)
Drive pinion shaft Hypoid driven gear Pinion shaft Straight pin Washer Differential bevel gear
(7) (8) (9) (10) (11) (12)
Differential bevel pinion Roller bearing Differential case Oil seal Differential side retainer O-ring
(13)
Retainer lock plate
5MT-12
General Description
7. TRANSMISSION MOUNTING
(4)
(7)
(3) T4 (2) (6)
T6 (1) T3 (9) T2 (8)
(3) (11) (2) (8) T2 (5) (10)
T5 T1
T7 T5
MT-01825
(1) (2) (3) (4) (5) (6) (7) (8)
Pitching stopper Spacer Lower cushion rubber Front plate Dynamic damper Transmission cushion rubber Rear crossmember Upper cushion rubber
(9) (10) (11)
Center crossmember Rear plate Front crossmember
Tightening torque:Nm (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: 35 (3.6, 25.8) T3: 50 (5.1, 36.9) T4: 58 (5.9, 42.8) T5: 70 (7.1, 51.6) T6: 75 (7.6, 55.3) T7: 140 (14.3, 103.3)
5MT-13
General Description
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry apart with screwdrivers or other tools. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine gear oil, grease or the equivalent. Do not mix gear oil, grease, etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Apply gear oil onto sliding or revolving surfaces before installation. Replace deformed or damaged snap rings with new parts. Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. Avoid damaging the mating surface of the case. Before applying liquid gasket, completely remove the liquid gasket.
5MT-14
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 399411700 DESCRIPTION ACCENT BALL INSTALLER REMARKS Used for installing reverse shifter rail arm.
ST-399411700
899524100
(1)
PULLER SET
Used for removing and installing the roller bearing (Differential). (1) Puller (2) Cap
(2)
ST-899524100
399780104
WEIGHT
Used for measuring preload on the roller bearing.
ST-399780104
498077000
REMOVER
Used for removing the roller bearing of the drive pinion shaft.
ST-498077000
5MT-15
General Description
ILLUSTRATION TOOL NUMBER 498077300 DESCRIPTION CENTER DIFFERENTIAL BEARING REMOVER REMARKS Used for removing the center differential cover ball bearing.
ST-498077300
498147001
DEPTH GAUGE
Used for measuring the free play of the main shaft.
ST-498147001
498247001
MAGNET BASE
Used for measuring backlash between the side gear and pinion, and the hypoid gear. Used together with DIAL GAUGE (498247100).
ST-498247001
498247100
DIAL GAUGE
Used for measuring backlash between the side gear and pinion, and the hypoid gear. Used together with MAGNET BASE (498247001).
ST-498247100
498427100
STOPPER
Used for securing the drive pinion shaft assembly and the driven gear assembly when removing the drive pinion shaft assembly lock nut.
ST-498427100
5MT-16
General Description
ILLUSTRATION TOOL NUMBER 498937000 DESCRIPTION TRANSMISSION HOLDER REMARKS Used for removing and installing the lock nut of the transmission main shaft.
ST-498937000
499277100
BUSHING 1-2 INSTALLER
Used for installing the 1st driven gear thrust plate and the 1st-2nd driven gear bushing. Used for installing the roller bearing outer race to the differential case.
ST-499277100
499277200
INSTALLER
Used for press-fitting the 2nd driven gear, roller bearings and the 5th driven gear onto the driven shaft.
ST-499277200
499757002
INSTALLER
Used for installing the snap ring (OUT 25), and ball bearing (25 26 17). Used for installing the bearing cone of the transfer driven gear (extension core side).
ST-499757002
18630AA010
Used for removing and installing the differential side retainer. WRENCH ASSEMBLY (499787000) can also be used.
ST18630AA010
5MT-17
General Description
ILLUSTRATION TOOL NUMBER 499857000 DESCRIPTION 5TH DRIVEN GEAR REMOVER REMARKS Used for removing the 5th driven gear.
ST-499857000
499877000
RACE 4-5 INSTALLER
Used for installing the 4th needle bearing race and ball bearing onto the transmission main shaft. Used together with REMOVER (899714110).
ST-499877000
499917500
DRIVE PINION GAUGE ASSY
Used for adjusting the drive pinion shim.
ST-499917500
499927100
HANDLE
Used for fitting the transmission main shaft.
ST-499927100
499937100
TRANSMISSION STAND
Used for disassembling and assembling the transmission.
ST-499937100
5MT-18
General Description
ILLUSTRATION TOOL NUMBER 499987003 DESCRIPTION SOCKET WRENCH (35) REMARKS Used for removing and installing the driven pinion lock nut and main shaft lock nut.
ST-499987003
499987300
SOCKET WRENCH (50)
Used for removing and installing the driven gear assembly lock nut.
ST-499987300
899714110
REMOVER
Used for fixing the transmission main shaft, drive pinion and rear drive shaft.
ST-899714110
899864100
REMOVER
Used for removing transmission main shaft and drive pinion parts.
ST-899864100
899884100
HOLDER
Used for tightening the lock nut on the sleeve.
ST-899884100
5MT-19
General Description
ILLUSTRATION TOOL NUMBER 899904100 DESCRIPTION REMOVER REMARKS Used for removing and installing the straight pin.
ST-899904100
899988608
SOCKET WRENCH (27)
ST-899988608
398497701
ADAPTER
Used for installing roller bearing onto the differential case. Used together with the BUSHING 1-2 INSTALLER (499277100).
ST-398497701
499587000
INSTALLER
Used for installing the driven gears to the driven shaft.
ST-499587000
498057300
INSTALLER
ST-498057300
5MT-20
General Description
ILLUSTRATION TOOL NUMBER 498255400 DESCRIPTION PLATE REMARKS Used for measuring backlash.
ST-498255400
41099AC000
ENGINE SUPPORT ASSY
Used for supporting the engine.
ST41099AC000
398527700
PULLER ASSY
Used for removing the extension case roller bearing.
ST-398527700
398643600
GAUGE
Used for measuring the total end play, extension end play and drive pinion height.
ST-398643600
398177700
INSTALLER
Used for installing the bearing cone of transfer driven gear (transfer case side). Used for installing the ball bearing of the transfer drive gear.
ST-398177700
5MT-21
General Description
ILLUSTRATION TOOL NUMBER 28399SA010 DESCRIPTION OIL SEAL PROTECTOR REMARKS Used for protecting the oil seal from damage when inserting the front drive shaft.
ST28399SA010
18675AA000
ST18675AA000
398791700
STRAIGHT PIN REMOVER 2
Used for installing and removing the straight pin.
ST-398791700
2. GENERAL TOOL
TOOL NAME Circuit tester TORX bit T70 REMARKS Used for measuring resistance, voltage and current. Used for installing and removing the differential gear oil drain plug.
5MT-22

2. Transmission Gear Oil

A: INSPECTION
1) Park the vehicle on a level surface. 2) Turn the ignition switch to OFF, and wait until the engine cools. 3) Remove the oil level gauge and wipe it clean. 4) Reinsert the oil level gauge all the way. Be sure that the oil level gauge is correctly inserted in the proper direction. 5) Pull out the oil level gauge again, and check the oil level. If it is at the lower level or less, add oil through the oil level gauge hole to bring the level up to the upper level.
(A)
B: REPLACEMENT
1) Pull out the oil level gauge. 2) Lift up the vehicle. 3) Using the TORX bit T70, remove the drain plug, and drain the transmission gear oil completely. CAUTION: Immediately after the engine has been running, the transmission gear oil will be hot. Be careful not to burn yourself. Be careful not to spill the transmission gear oil on exhaust pipe to prevent it from emitting smoke or causing fires. If gear oil is spilled, wipe it off completely. 4) Using the TORX bit T70, tighten the transmission gear oil drain plug. NOTE: Tighten the drain plug of the transmission gear oil after draining the transmission gear oil. Use a new gasket. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
(B) (C)
PM-00030
MT-01548
5) Lower the vehicle. 6) Pour gear oil through the oil level gauge hole. Recommended gear oil: GL-5 (75W-90) or equivalent Gear oil capacity: 3.5 2 (3.7 US qt, 3.1 Imp qt) 7) Measure the transmission gear oil amount, and check that it is within the specification. CAUTION: When inserting the oil level gauge into the transmission, align the protrusion on top of the oil level gauge with the notch in the oil level gauge hole.
5MT-23
Manual Transmission Assembly

3. Manual Transmission Assembly

A: REMOVAL
1) Set the vehicle on a lift. 2) Open the front hood fully, and support with stay. 3) Disconnect the ground cable from the battery. 4) Drain transmission gear oil completely. <Ref. to 5MT-23, REPLACEMENT, Transmission Gear Oil.> 5) Remove the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 6) Remove the air intake chamber stay. (Non-turbo model)
7) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 8) Disconnect the connector back-up light switch & neutral position switch. Non-turbo model
(A)
(B)
MT-00104
(A) Neutral position switch connector (Brown) (B) Back-up light switch connector (Gray)
Turbo model
MT-00062
MT-00105
9) Disconnect the ground cable.
MT-01814
10) Remove the starter. <Ref. to SC(H4SO)-6, REMOVAL, Starter.>
5MT-24

11) Remove the operating cylinder from the transmission, and suspend on a wire.
17) Remove the rear exhaust pipe and muffler. Non-turbo model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> Turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> CAUTION: When removing the exhaust pipes, be careful each exhaust pipe does not drop out. 18) Remove the bolts which hold upper side of transmission to engine.
MT-01220
MT-01556
13) Set the ST. ST 41099AC000 ENGINE SUPPORT ASSY
MT-01524
ST
MT-01226
MT-01660
14) Lift up the vehicle. 15) Remove the front and center exhaust pipes. (Non-turbo model) <Ref. to EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.> 16) Remove the center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.>
20) Remove the hanger bracket from the right side of transmission.
MT-00074
5MT-25

22) Remove the gear shift rod and the stay from the transmission. (1) Disconnect the stay from the transmission. (2) Remove the gear shift rod from the transmission.
25) Using a crowbar, remove the left and right front drive shaft from the transmission.
(A) (B) (B) (A) MT-01017
(A) Bar
MT-00075
(A) Stay (B) Gear shift rod
26) Remove the bolts and nuts which hold lower side of transmission to engine.
23) Remove the stabilizer link from the front arm.
MT-00077
27) Place the transmission jack under the transmission.

MT-00988
24) Remove the bolt securing the ball joint of the front arm to the housing, then separate the front arms and the housing.
(B)
CAUTION: Always support the transmission case with a transmission jack.
(C) (A) MT-00987 MT-00078
(A) Front arm (B) Ball joint (C) Stabilizer link
5MT-26

28) Remove the front crossmember and rear crossmember from the vehicle.
B: INSTALLATION
1) Replace the differential side retainer oil seal. <Ref. to 5MT-34, REPLACEMENT, Differential Side Retainer Oil Seal.> ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Be sure to replace the differential side retainer oil seal after the removing the front drive shaft.
MT-01671
ST
29) Tighten the turnbuckle of the ST while lowering the transmission jack, to tilt the engine assembly towards the back. 30) Remove the transmission. NOTE: Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc. 31) Separate the transmission assembly from the transmission cushion rubber.
MT-00103
2) Install the transmission cushion rubber to the transmission assembly, and tighten bolt (A). 3) Install the transmission cushion rubber to the center crossmember, and tighten the nut (B). Tightening torque: Bolt (A) 35 Nm (3.6 kgf-m, 25.8 ft-lb) Nut (B) 35 Nm (3.6 kgf-m, 25.8 ft-lb)
(A) (A)
(B)
MT-01676
4) Install the transmission onto the engine. (1) Lift up the transmission gradually using a transmission jack. (2) Engage at the spline section. NOTE: Be careful not to hit the main shaft against the clutch housing cover. 5) While raising the transmission jack, loosen the turnbuckle of the ST, and set the engine unit to the original position.
5MT-27

6) Install the front crossmember and rear crossmember. Tightening torque: T1: 75 Nm (7.6 kgf-m, 55.3 ft-lb) T2: 140 Nm (14.3 kgf-m, 103.3 ft-lb)
T1 T1
10) Remove the ST.
ST
T2
T2
MT-01226
MT-01672
7) Take out the transmission jack. 8) Tighten the bolts and nuts which hold the lower side of the transmission to the engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2 T1
MT-01557
12) Lift up the vehicle. 13) Install the front drive shaft into the transmission. ST 28399SA010 OIL SEAL PROTECTOR
MT-00077
9) Connect the transmission to the engine. (1) Install the starter. <Ref. to SC(H4SO)-6, INSTALLATION, Starter.> (2) Tighten the bolts which hold the upper side of the transmission to the engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
ST AT-00110
MT-01524
5MT-28

14) Insert the ball joints of the front arm into the housing, then tighten the installing bolts. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
(B)
(C) MT-01660 (A) MT-00987
19) Install the hanger bracket on the right side of the transmission.
(A) Front arm (B) Ball joint (C) Stabilizer link
15) Attach the stabilizer link to the front arm. Tightening torque: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
MT-00074
MT-00988
16) Attach the gear shift rod and stay. (1) Attach the gear shift rod to the transmission. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A) (B) (B)
20) Install the rear exhaust pipe and muffler. Non-turbo model <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> Turbo model <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 21) Install the front and center exhaust pipe. (Nonturbo model) <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> 22) Install the center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.>
MT-00089
(A) Stay (B) Gear shift rod
(2) Attach the stay to the transmission. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
5MT-29

23) Install the operating cylinder. Tightening torque: 37 Nm (3.8 kgf-m, 27.3 ft-lb)
MT-01220
24) Connect the following connectors. (1) Transmission ground cable Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb) (2) Neutral position switch connector (3) Back-up light switch connector 25) Fill transmission gear oil through the transmission oil level gauge hole. <Ref. to 5MT-23, Transmission Gear Oil.> 26) Install the air intake chamber stay. (Non-turbo model) Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb) 27) Install the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 28) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 29) Connect the ground cable to battery.
5MT-30

4. Transmission Mounting System

A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from the battery. 2) Remove the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 3) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 4) Remove the pitching stopper.
7) Set the transmission jack under the transmission body. CAUTION: Always support the transmission case with a transmission jack. 8) Remove the front and rear crossmembers.
MT-01671
9) Remove the transmission cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
1) Install the pitching stopper.
MT-01556
2. CROSSMEMBER AND CUSHION RUBBER

1) Disconnect the ground cable from the battery. 2) Lift up the vehicle. 3) Remove the front and center exhaust pipes. (Non-turbo model) <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.> 4) Remove the center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 5) Remove the rear exhaust pipe and muffler. Non-turbo model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> Turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 6) Remove the heat shield cover.
Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
T1
T2
MT-01557
2) Install the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 3) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 4) Connect the ground cable to battery.
MT-01660
5MT-31


1) Install the transmission cushion rubber to the transmission, and tighten the bolt (A). 2) Attach the transmission cushion rubber to the center crossmember, and tighten nut (B). Tightening torque: Bolt (A) 35 Nm (3.6 kgf-m, 25.8 ft-lb) Nut (B) 35 Nm (3.6 kgf-m, 25.8 ft-lb)
7) Install the center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> 8) Install the rear exhaust pipe and muffler. Non-turbo model <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> Turbo model <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 9) Lower the vehicle. 10) Connect the ground cable to battery.
C: INSPECTION
(A) (A)
Perform the following inspection procedures and repair or replace faulty parts.
1. PITCHING STOPPER
(B) MT-01676
T1 T1
Check the pitching stopper for bends or damage. Check that the rubber is not stiff, cracked or otherwise damaged.

Check crossmember for bends or damage. Check that the cushion rubber is not stiff, cracked, or otherwise damaged.
T2
T2
MT-01672
4) Remove the transmission jack. 5) Install the heat shield cover.
MT-01660
6) Install the front and center exhaust pipe. (Nonturbo model) <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.>
5MT-32
Oil Seal
5. Oil Seal
A: INSPECTION
Check for leakage of gear oil from the oil seal. If there is oil leakage, replace the oil seal with the new part and check the propeller shaft.
7) Remove the oil seal using ST. ST 398527700 PULLER ASSY

(A) ST
B: REPLACEMENT
1) Clean the transmission exterior. 2) Using the TORX bit T70, remove the drain plug, and drain the transmission gear oil completely. 3) Using the TORX bit T70, tighten the transmission gear oil drain plug. NOTE: Use a new gasket. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
MT-00098
(A) Oil seal
8) Using the ST, install the oil seal. ST 498057300 INSTALLER

ST
MT-01299
MT-01548
4) Remove the rear exhaust pipe and muffler. Non-turbo model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> Turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 5) Remove the heat shield cover.
MT-01660
MT-01660
11) Install the rear exhaust pipe and muffler. Non-turbo model <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> Turbo model <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 12) Pour in the transmission gear oil and check the oil level. <Ref. to 5MT-23, Transmission Gear Oil.>
5MT-33

6. Differential Side Retainer Oil Seal

A: INSPECTION
Check for leakage of gear oil from the differential side retainer oil seal. If there is oil leakage, replace the oil seal with the new part and check the drive shaft.
7) Remove the differential side retainer oil seal. NOTE: Be sure to replace the differential side retainer oil seal whenever the front drive shaft is removed from the transmission. To remove the oil seal, use ST 398527700 PULLER ASSY. When removing the part by using a flat tip screwdriver, be careful not to scratch the differential side retainer. 8) Using the ST, install the differential side retainer oil seal by lightly tapping with a plastic hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Apply differential gear oil to the oil seal lips.
ST
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the differential gear oil drain plug using TORX bit T70, and drain the differential gear oil completely.
MT-01548
3) Replace the gasket with a new part and tighten the differential gear oil drain plug using the TORX bit T70. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
MT-00103
9) Install the front drive shaft. <Ref. to DS-22, INSTALLATION, Front Drive Shaft.> 10) Install the front and center exhaust pipe. (Nonturbo model) <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.> 11) Install the center exhaust pipe. <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> 12) Lower the vehicle. 13) Fill transmission gear oil through the oil level gauge hole. <Ref. to 5MT-23, Transmission Gear Oil.>
MT-01548
4) Remove the front and center exhaust pipes. (Non-turbo model) <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO)-7, REMOVAL, Center Exhaust Pipe.> 5) Remove the center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 6) Separate the front drive shaft from the transmission. <Ref. to DS-22, REMOVAL, Front Drive Shaft.>
5MT-34
Switches and Harness

7. Switches and Harness

A: REMOVAL
1. BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH
1) Disconnect the ground cable from the battery. 2) Remove the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 3) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 4) Disconnect the connector back-up light switch & neutral position switch. Non-turbo model
6) Remove the back-up light switch & neutral position switch with the harness.
(A)
(B) MT-00106
(A) Neutral position switch (B) Back-up light switch
B: INSTALLATION
(A)
1. BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH

(B)
1) Install the back-up light switch & neutral position switch with the harness. Tightening torque: 32.3 Nm (3.3 kgf-m, 23.8 ft-lb)
MT-00104
(A) Neutral position switch connector (Brown) (B) Back-up light switch connector (Gray)
(A)
Turbo model
(B) MT-00106
(A) Neutral position switch (B) Back-up light switch
MT-00105
2) Connect the connectors of back-up light switch and neutral position switch. 3) Install the air intake chamber and intake boot. (Non-turbo model) <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 4) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 5) Connect the ground cable to battery.
5MT-35
Switches and Harness

C: INSPECTION
1. BACK-UP LIGHT SWITCH
Check the back-up light switch. <Ref. to LI-8, INSPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH

1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals. Non-turbo model
2 1
MT-00110
Gear shift position Neutral position Other positions
Specified resistance Less than 1 : 1 M: or more
Turbo model
2 1 4 3
MT-00111
Gear shift position Neutral position Other positions
Specified resistance Less than 1 : 1 M: or more
4) Replace faulty parts.
5MT-36

8. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from the transmission. 2) Using the TORX bit T70, remove the drain plug of the transmission gear oil, and drain the transmission gear oil completely. 3) Using the TORX bit T70, tighten the transmission gear oil drain plug. NOTE: Use a new gasket. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
MT-01548
4) Attach the transmission to ST. ST 499937100 TRANSMISSION STAND
ST
MT-00115
5) Apply oil to rotating parts before assembly. 6) All disassembled parts, if to be reused, should be reinstalled in the original positions and directions. 7) Gaskets, lock washers and lock nuts must be replaced with new ones. 8) Apply liquid gasket to the specified areas to prevent leakage.
5MT-37
Transfer Case and Extension Case Assembly

9. Transfer Case and Extension Case Assembly

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch neutral position switch. <Ref. to 5MT-35, REMOVAL, Switches and Harness.> 3) Remove the transfer case together with the extension case assembly.
B: INSTALLATION
1) Install the center differential and transfer driven gear into the transfer case.
MT-00118
2) Remove the bearing outer race from the extension case.

(B)
(A)
MT-00116
4) Remove the shifter arm. 5) Remove the extension case assembly.

MT-00119
(A) Bearing outer race (B) Extension Case
3) While holding the bearing outer race horizontally, rotate the driven shaft for ten turns. 4) Measure the height W between transfer case and taper roller bearing on the transfer driven gear.
MT-00117
MT-00120
W Measured value
5MT-38

5) Measure depth X on bearing insertion part of the extension case. NOTE: Measure with bearing outer race and thrust washer removed.
8) Fit the thrust washers on the transfer drive shaft. 9) Install the bearing outer race into the extension case. 10) Measure the depth S between transfer case and center differential. ST 398643600 GAUGE
ST
S X
MT-00121 MT-00122
X Measured value
S Measured value
6) Calculate the thrust washer thickness t using the following calculation. t = X W + (0.15 0.25 mm (0.006 0.010 in)) 7) Select the washer with the nearest value in the following table. Preload (standard protrusion) of the taper roller bearing: 0.15 0.25 mm (0.006 0.010 in) NOTE: Be sure that the preload is always within the standard.
Thrust washer (50 61 t) Part number Thickness mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217) 803050062 0.60 (0.0236) 803050063 0.65 (0.0256) 803050064 0.70 (0.0276) 803050065 0.75 (0.0295) 803050066 0.80 (0.0315) 803050067 0.85 (0.0335) 803050068 0.90 (0.0354) 803050069 0.95 (0.0374) 803050070 1.00 (0.0394) 803050071 1.05 (0.0413) 803050072 1.10 (0.0433) 803050073 1.15 (0.0453) 803050074 1.20 (0.0472) 803050075 1.25 (0.0492) 803050076 1.30 (0.0512) 803050077 1.35 (0.0531) 803050078 1.40 (0.0551) 803050079 1.45 (0.0571)
11) Measure the height T between the extension case and transfer drive gear. ST 398643600 GAUGE
ST
MT-00123
T Measured value
NOTE: Thickness of ST: 15 mm (0.59 in) 12) Calculate the thrust washer thickness U using the following calculation. U = S + T 30 mm (1.18 in) [Thickness of ST]
5MT-39

13) Select a suitable washer in the following table. Standard clearance: 0.15 0.35 mm (0.0059 0.0138 in)
Thrust washer Part number Thickness mm (in) 803036050 0.9 (0.035) 803036054 1.0 (0.039) 803036051 1.1 (0.043) 803036055 1.2 (0.047) 803036052 1.3 (0.051) 803036056 1.4 (0.055) 803036053 1.5 (0.059) 803036057 1.6 (0.063) 803036058 1.7 (0.067) 803036080 1.8 (0.071) 803036081 1.9 (0.075)
17) Attach the shifter arm to transfer case.
MT-00126
18) Hang the shifter arm on 3rd-4th fork rod.

(A)
14) Fit the thrust washer onto the center differential. 15) Apply a proper amount of liquid gasket to the transfer case mating surface. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
(A) Shifter arm (B) 3rd-4th fork rod
(B)
MT-00127
19) Install the extension case assembly along with the transfer case to the transmission case. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
MT-00124
16) Install the extension assembly into the transfer case. Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
MT-00116
MT-00117
5MT-40

C: DISASSEMBLY
1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to 5MT-47, REMOVAL, Reverse Check Sleeve.> 2) Remove the oil guide.
D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, install the oil seal to the extension case. <Ref. to 5MT-33, Oil Seal.> NOTE: Use a new oil seal. 2) Install the shift bracket to extension case. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
MT-01563
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref. to 5MT-42, REMOVAL, Transfer Drive Gear.> 2) Remove the shift bracket.
MT-00130
3) Install the transfer drive gear to the extension case. <Ref. to 5MT-42, INSTALLATION, Transfer Drive Gear.>
2. TRANSFER CASE
1) Install the oil guide to the transfer case. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
MT-00130
3) Remove the oil seal from the extension case. <Ref. to 5MT-33, Oil Seal.>
NOTE: Use a new installing bolt.
MT-01563
2) Install the reverse check sleeve assembly to the transfer case. <Ref. to 5MT-47, INSTALLATION, Reverse Check Sleeve.>
5MT-41
Transfer Drive Gear

10.Transfer Drive Gear

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch neutral position switch. <Ref. to 5MT-35, REMOVAL, Switches and Harness.> 3) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the extension case assembly. 5) Remove the transfer driven gear. <Ref. to 5MT44, REMOVAL, Transfer Driven Gear.> 6) Remove the transfer drive gear.
C: DISASSEMBLY
MT-00135
2) Remove the ball bearing.
MT-00136
D: ASSEMBLY
MT-00133
B: INSTALLATION
1) Attach the transfer drive gear. Tightening torque: 26 Nm (2.7 kgf-m, 19.2 ft-lb)
1) Set the ST against the inner race of the bearing, and install the drive shaft. ST 398177700 INSTALLER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST
MT-00133
MT-00137
2) Install the transfer driven gear. <Ref. to 5MT-44, INSTALLATION, Transfer Driven Gear.> 3) Install the extension case assembly. 4) Install the transfer case and the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 5) Install the back-up light switch neutral position switch. <Ref. to 5MT-35, INSTALLATION, Switches and Harness.> 6) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
2) Install the snap ring on the transfer drive shaft. 3) Inspect the clearance between the snap ring and the ball bearing. <Ref. to 5MT-43, INSPECTION, Transfer Drive Gear.>
5MT-42
Transfer Drive Gear

E: INSPECTION
1) Bearing Replace the bearings in the following cases. In case of broken or rusty bearings In case of worn or damaged bearings When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. 2) Drive gear If the drive gear tooth surface and shaft are excessively broken or damaged, replace the drive gear. 3) Measure the clearance between snap ring and inner race of ball bearing with a thickness gauge. Clearance: 0.01 0.15 mm (0.0004 0.0059 in)
MT-00138
If the measurement is not within specification, select a suitable snap ring and replace it.
Snap ring (Outer-30) Part number Thickness mm (in) 805030041 1.53 (0.0602) 805030042 1.65 (0.0650) 805030043 1.77 (0.0697)
5MT-43
Transfer Driven Gear

11.Transfer Driven Gear

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch neutral position switch. <Ref. to 5MT-35, REMOVAL, Switches and Harness.> 3) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the extension case assembly. 5) Remove the transfer driven gear.
B: INSTALLATION
1) Install the bearing outer races to extension case and transfer case.
(C)
(A)
(B)
(D)
MT-00118
MT-00141
6) Remove bearing outer races from the extension case and transfer case.
(A) (B) (C) (D)
Bearing outer race Bearing outer race Transfer case Extension Case
(A)
2) Install the transfer driven gear.
(B) MT-00118
MT-00140
(A) Bearing outer race (Transfer case side) (B) Bearing outer race (Extension case side)
3) Install the transfer case and the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 4) Install the back-up light switch neutral position switch. <Ref. to 5MT-35, INSTALLATION, Switches and Harness.> 5) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
5MT-44

C: DISASSEMBLY
1) Using the ST, remove the roller bearing (extension case side). ST 498077000 REMOVER
D: ASSEMBLY
1) Using the ST, install the roller bearing (extension case side). ST1 398177700 INSTALLER ST2 899864100 REMOVER CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
(A)
ST ST2
MT-00143
(A) Roller bearing
(A)
ST1
2) Using ST1 and ST2, remove the roller bearing (transfer case side). ST1 498077000 REMOVER ST2 899864100 REMOVER
MT-00145
(A) Roller bearing
ST2
2) Using ST, install the roller bearing (transfer case side). ST 499757002 INSTALLER CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST MT-00144 (A)
(A) ST1
(A) Roller bearing
MT-00146
(A) Roller bearing
E: INSPECTION
1) Bearing Replace the bearings in the following cases. In case of broken or rusty bearings In case of worn or damaged bearings When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. 2) Driven gear If the driven gear tooth surface and shaft are excessively broken or damaged, replace the driven gear.
5MT-45
Center Differential
12.Center Differential
A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch neutral position switch. <Ref. to 5MT-35, REMOVAL, Switches and Harness.> 3) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 5) Remove the transfer driven gear. <Ref. to 5MT44, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential.
C: DISASSEMBLY
NOTE: Center differential is a non-disassembled part which should not be disassembled. Remove the ball bearing using ST. NOTE: Do not reuse the ball bearing. ST 498077300 CENTER DIFFERENTIAL BEARING REMOVER
ST
B: INSTALLATION
1) Install the center differential into transfer case. 2) Install the transfer driven gear. <Ref. to 5MT-44, INSTALLATION, Transfer Driven Gear.> 3) Install the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 4) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 5) Install the back-up light switch neutral position switch. <Ref. to 5MT-35, INSTALLATION, Switches and Harness.> 6) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
MT-00147
D: ASSEMBLY
Install the ball bearing into the center differential assembly. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
(A) MT-00148
(A) Ball bearing
E: INSPECTION
1) Bearing Replace the bearings in the following cases. In case of broken or rusty bearings In case of worn or damaged bearings When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. When bearing has other defects. 2) Center differential Replace the center differential case assembly if worn or damaged.
5MT-46
Reverse Check Sleeve

13.Reverse Check Sleeve

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove the shifter arm. 4) Remove the plug, gasket, reverse accent spring, and reverse check ball.
B: INSTALLATION
1) Install the reverse check sleeve. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
MT-00150
2) Install the reverse check ball, reverse accent spring, gasket, and plug to the transfer case. Tightening torque: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
MT-00149
5) Remove the reverse check sleeve.
MT-00149
MT-00150
3) Attach the shifter arm to the transfer case assembly. 4) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 5) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
5MT-47

C: DISASSEMBLY
1) Cover the reverse check sleeve with a rag, and remove the snap ring using a screwdriver. NOTE: Replace the snap ring with a new part if it is deformed or spring force is weakened.
(A)
D: ASSEMBLY
1) Install the return spring (1st-2nd), return spring cap, reverse accent shaft, reverse check cam, return spring (5th-Rev) and reverse check spring to the reverse check sleeve. NOTE: Be sure to position the bent section of reverse check spring to fit in the groove of the check cam.
(A) (C) (B) (D) (F) MT-00153 (E) (G)
(A) Snap ring
MT-00154
2) Remove the reverse check plate, reverse check spring, reverse check cam, return spring (5th-Rev), reverse accent shaft, return spring cap and return spring (1st-2nd).
(A) (C) (B) (D) (F) (E) (G)
(A) (B) (C) (D) (E) (F) (G)
Reverse check plate Reverse check spring Return spring (5th-Rev) Reverse check cam Reverse accent shaft Return spring cap Return spring (1st-2nd)
MT-00154
(A) (B) (C) (D) (E) (F) (G)
Reverse check plate Reverse check spring Return spring (5th-Rev) Reverse check cam Reverse accent shaft Return spring cap Return spring (1st-2nd)
2) Hook the curved section of the reverse check spring over the reverse check plate. 3) Rotate the cam so that the protrusion of the reverse check cam comes to the opening of the plate. 4) With cam held in that position, install the reverse check plate onto the reverse check sleeve and hold in place with the snap ring. 5) Position the new O-ring in the groove of sleeve.
3) Remove the O-ring. NOTE: Visually check the O-ring. Replace if faulty. Be careful not to damage the adjusting shim between reverse check sleeve assembly and the case.
5MT-48

E: INSPECTION
Check that the cutout of the reverse accent shaft is aligned with the opening of the reverse check sleeve. Turn the cam by hand to check for smooth rotation. Move the cam and shaft all the way toward the plate, and make sure it releases. If the cam does not return properly, replace the reverse check spring. If the shaft does not return, check for scratches on the inner surface of sleeve. If the sleeve is in good order, replace the spring.
(D) (C)
F: ADJUSTMENT
1. NEUTRAL POSITION ADJUSTMENT
1) Shift the gear into 3rd gear position. 2) Because of the return spring, until the arm contacts the stopper the shifter arm will feel lighter moving towards 1st/2nd gear and heavier towards the reverse gear. 3) Make adjustment so that the heavy stroke (reverse side) is a little heavier than the lighter stroke (1st/2nd side). 4) To adjust, remove the bolts holding the reverse check sleeve assembly to the case, and move the sleeve assembly outward, then place an adjustment shim between the sleeve assembly and the case to adjust the clearance. CAUTION: Be careful not to damage the O-ring when placing shims.
(A) (B) MT-00156
(A) (B) (C) (D)
Snap ring Reverse check plate Reverse check spring Reverse check cam
NOTE: When the shim is removed, the neutral position will move closer to reverse; when the shim is added, the neutral position will move closer to 1st gear. If it is not possible to adjust the clearance with only shims, replace the reverse accent shaft and re-adjust.
Adjusting shim Part No. Thickness mm (in) 32190AA000 0.15 (0.0059) 32190AA010 0.30 (0.0118) Reverse accent shaft Part number 32188AA130 32188AA140 32188AA150 Mark S T U Remarks Neutral position is closer to 1st. Standard Neutral position is closer to reverse gear.
Select a suitable reverse accent shaft and reverse check plate. <Ref. to 5MT-49, ADJUSTMENT, Reverse Check Sleeve.>
5MT-49

2. REVERSE CHECK PLATE ADJUSTMENT

1) Shift the shifter arm to 5th and then to reverse to see if the reverse check mechanism operates properly. 2) Also check to see if the arm returns to neutral when released from the reverse position. If the arm does not return properly, replace the reverse check plate.
Reverse check plate Part number 32189AA001 32189AA011 32189AA021 32189AA031 32189AA041 (A): No. 0 1 2 3 4 AngleT 28 31 34 37 40 Remarks Arm stops closer to 5th gear. Arm stops closer to 5th gear. Arm stops in the center. Arm stops closer to reverse gear. Arm stops closer to reverse gear.
(A)
MT-00157
5MT-50
Transmission Case
14.Transmission Case
A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the clutch release lever. <Ref. to CL18, REMOVAL, Release Bearing and Lever.> 3) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the bearing mounting bolt.
7) Remove the drive pinion shaft assembly from the left side of the transmission case. NOTE: Use a hammer handle, etc. to remove if too tight.
(A) (B)
MT-00161
(A) Main shaft ASSY for single-range (B) Drive pinion shaft ASSY
8) Remove the main shaft assembly for singlerange. 9) Remove the front differential assembly.
MT-01514
5) Remove the main shaft rear plate.

(A)
NOTE: Do not confuse the right and left roller bearing outer races. Be careful not to damage the oil seal of retainer.
MT-01515 MT-00162
(A) Main shaft rear plate
6) Separate the transmission case into the right and left cases by loosening the coupling bolts and nuts.
MT-00160
5MT-51
Transmission Case
B: INSTALLATION
1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with cleaning solvent. 2) Install the front differential assembly. 3) Install the main shaft assembly for single-range. Install the transmission case knock pin into the knock pin hole of needle bearing. 4) Install the drive pinion shaft assembly. Install the transmission case knock pin into the roller bearing knock pin hole. 5) Apply liquid gasket, then join the right side and left side of the case together. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent 6) With brackets and clips as shown in the figure, tighten the seventeen bolts. NOTE: Insert the bolts from the bottom and tighten the nuts at the top. Match the cases together so that the drive pinion shim and input shaft holder shims are not caught between the case halves. Tightening torque: 8 mm bolt 25 Nm (2.5 kgf-m, 18.4 ft-lb) 10 mm bolt 39 Nm (4.0 kgf-m, 28.8 ft-lb)
(16) (9) (13) (1) (2) (15) (14) (10) (6) (8) (12) (4) MT-00172 (3) (5) (7) (17) (11)
8) Perform backlash adjustment of the hypoid gear and preload measurement of the roller bearing. NOTE: Attach the ST on drive pinion assembly. ST 498427100 STOPPER
ST MT-01516
9) Place the transmission with the left side of case facing downward, and put ST1 on bearing cup. 10) Screw the retainer assembly from the bottom into left case using ST2. Fit the ST3 on transmission main shaft. Shift the gear into 4th or 5th, and turn the shaft several times. Screw in the retainer while rotating the ST3 until a slight resistance is felt on ST2. This is the contact point of the hypoid gear and the drive pinion shaft. Repeat the above sequence several times to ensure the contact point. ST1 399780104 WEIGHT ST2 18630AA010 WRENCH COMPL RETAINER ST3 499927100 HANDLE
ST1 ST2 ST3
MT-00175
7) Tighten the ball bearing mounting bolts. Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft-lb)
MT-01514
5MT-52
Transmission Case
11) Remove the weight, and screw in the retainer without the O-ring on the upper side, and stop at the point where a slight resistance is felt. NOTE: In this condition, the backlash between the hypoid gear and drive pinion shaft is zero. ST 18630AA010 WRENCH COMPL RETAINER
ST
17) After checking the tooth contact of the hypoid gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the Oring into the groove and tighten the retainer into the position where retainer was tightened to. Install the lock plate. NOTE: When loosening the retainer, record how many times it was turned to loosen. Perform this for both upper and lower retainers. Tightening torque: T: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00176
12) Loosen the retainer on the lower side by 3 notches, and turn the retainer on the upper side by the same amount in order to apply backlash. 13) Rotate the retainer of the upper side additionally by 1 notch in order to apply preload on taper roller bearing. 14) Temporarily attach both the upper and lower lock plates, and put marks both the retainer and lock plate for later readjustment. NOTE: If it is hard to install the lock plates, reverse the sides and install them. 15) Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer. 16) Inspect and adjust backlash and tooth contact of the hypoid gear. <Ref. to 5MT-73, INSPECTION, Front Differential Assembly.>
T MT-00177
18) Select the main shaft rear plate. <Ref. to 5MT59, ADJUSTMENT, Main Shaft Assembly for Single-Range.> 19) Install the clutch release lever and bearing. <Ref. to CL-19, INSTALLATION, Release Bearing and Lever.> 20) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 21) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
C: INSPECTION
Check the transmission case for cracks, damage, or oil leaks.
5MT-53
Main Shaft Assembly for Single-Range

15.Main Shaft Assembly for Single-Range

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove the transmission case. <Ref. to 5MT51, REMOVAL, Transmission Case.> 4) Remove the drive pinion shaft assembly. <Ref. to 5MT-60, REMOVAL, Drive Pinion Shaft Assembly.> 5) Remove the main shaft assembly for singlerange.
6) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
C: DISASSEMBLY
1) Apply vinyl tape around the main shaft splines to protect the oil seal from damage. Then pull out the oil seal and needle bearing by hand. 2) Remove the lock nut from transmission main shaft assembly for single range. NOTE: Flatten the lock nut tab before removing the lock nut. ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH (35)
B: INSTALLATION
1) Install the needle bearing and oil seal to the front of the transmission single-range main shaft assembly. NOTE: Wrap the clutch splined section with vinyl tape to prevent damage to the oil seal. Apply KOPR-KOTE (or equivalent) to the sealing lip of the oil seal. Use a new oil seal. 2) Install the transmission case knock pin into the knock pin hole of the needle bearing outer race. NOTE: Align the end face of the seal with surface (A) when installing the oil seal.
ST2 ST1 MT-01517
3) Remove the 5th hub & sleeve No. 2, baulk lever, baulk ring, and the 5th drive gear & needle bearing.
(C) (B) (A)
MT-01518
(A) 5th hub & sleeve No. 2 (B) Baulk ring (C) 5th drive gear
(A) MT-00185
3) Install the drive pinion shaft assembly. <Ref. to 5MT-60, INSTALLATION, Drive Pinion Shaft Assembly.> 4) Install the transmission case. <Ref. to 5MT-52, INSTALLATION, Transmission Case.> 5) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.>
5MT-54

4) Using ST1 and ST2, remove the rest of the parts. NOTE: When replacing the sleeve & hub, replace them as a set. Do not disassemble the sleeve & hub; the aligning position is pre-matched. If it is necessary to disassemble, mark the engaging points on the splines beforehand. ST1 899864100 REMOVER ST2 899714110 REMOVER
(A)
D: ASSEMBLY
1) When the sleeve & hub assemblies have been disassembled, reassemble by aligning the alignment marks. NOTE: Position the spring opening at a position spaced apart by 120.
(A)
ST1 (B)
(C)
ST2
(D) MT-01523
MT-01806
(A) Press
(A) (B) (C) (D)
3rd-4th hub ASSY 3rd gear side 5th hub & sleeve No. 2 5th gear side
5MT-55

2) Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly for the 3rd needle bearing, on the transmission main shaft. NOTE: Align the groove in baulk ring with the shifting insert.
(A) (D) (E)
4) Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft. NOTE: Align the baulk ring and gear & hub assembly with the key groove.
(A) (B) MT-00193 (B) (C) (F) MT-01318
(A) (B) (C) (D) (E) (F)
3rd needle bearing 3rd drive gear Inner baulk ring Synchro cone Outer baulk ring Sleeve & hub ASSY
(A) Groove (B) Face this surface to the 4th gear side.
5) Press-fit the ball bearing into the rear section of transmission main shaft using ST1, ST2 and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER
ST2
3) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER
ST2 (A) ST1
ST1
MT-00194
MT-00192
(A) 4th needle bearing race
5MT-56

6) Using the ST1 and ST2, install the 5th needle bearing race onto the rear section of the transmission main shaft. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Make sure the thrust washer is facing the correct direction. ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER
7) Install rest of the parts to the rear section of the transmission main shaft. CAUTION: Attach the baulk lever with the narrower side facing the 5th hub side.
(A)
(B)
MT-01522 (A)
(A) Baulk lever (B) 5th hub
Align the protruded section of baulk ring between the baulk levers.
MT-00195 (B)
(A) Face this surface to the 5th gear side.
(C) (A) (B) MT-01531
(A) Baulk ring (B) Baulk lever (C) 5th hub
(A) (B) (C)
(D) (G) (E) (F)
MT-01627
(A) (B) (C) (D) (E) (F) (G)
Needle bearing 5th drive gear Baulk ring 5th hub & sleeve No. 2 Lock washer Lock nut Baulk lever
5MT-57

8) Tighten the lock nuts to the specified torque using ST1 and ST2. 9) Crimp lock nuts in two locations after tightening. ST1 499987003 SOCKET WRENCH (35) ST2 498937000 TRANSMISSION HOLDER Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb)
E: INSPECTION
Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully. 1) Bearing Replace the bearings in the following cases. When the bearing balls, outer races and inner races are broken or rusty. When the bearing is worn. When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. When the bearing has other problems. 2) Bushing (each gear) Replace the bushing in following cases. When the sliding surface is damaged or abnormally worn. When the inner wall is abnormally worn. 3) Gear Replace gears in the following cases. Replace the gear with new part if its tooth surfaces are broken, damaged or excessively worn. Correct or replace if the cone that contacts the baulk ring is rough or damaged. Correct or replace if the inner surface or end face is damaged.
4) Baulk ring Replace the baulk rings in the following cases. When the inner surface and end face are damaged. When the ring inner surface is abnormally or partially worn down. When the contact surface of the synchronizer ring insert section is cracked or abnormally worn. If the gap between the end faces of the ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone. Clearance (A): 0.5 mm (0.020 in) or more
(A)
MT-01674
(A) Measured value
5) Shifting insert key Replace the insert key if deformed, excessively worn or defective in any way.
MT-01213
6) Oil seal Replace the oil seal if the lip is deformed, hardened, worn or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn or defective in any way. 8) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
5MT-58

F: ADJUSTMENT
Selection of main shaft rear plate: Using the ST, measure the protrusion amount (A) of ball bearing from transmission main case surface, and select a suitable plate in the following table. NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and moving flange of bearing. ST 498147001 DEPTH GAUGE
Dimension (A) mm (in) 4.00 4.13 (0.1575 0.1626) 3.87 4.00 (0.1524 0.1575) Part number 32294AA041 32294AA051 Mark 1 2
Turbo model
(A)
MT-01807
(A) Measured value
Non-turbo model
(A)
MT-00209
(A) Measured value
5MT-59


A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove the transmission case. <Ref. to 5MT51, REMOVAL, Transmission Case.> 4) Remove the drive pinion shaft assembly. NOTE: Use a hammer handle, etc. to remove if too tight.
(A) (B)
4) Check and adjust the ST. NOTE: Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level. Tighten the two bolts. ST 499917500 DRIVE PINION GAUGE ASSY
(A)
ST
(B) MT-00242
(A) Plate (B) Scale
MT-00161
(A) Main shaft ASSY for single range (B) Drive pinion shaft ASSY
B: INSTALLATION
1) Remove the front differential assembly. 2) Alignment marks/numbers on hypoid gear set: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers. The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.
(A)
5) Position the ST by inserting the knock pin of ST into the knock hole of transmission case. ST 499917500 DRIVE PINION GAUGE ASSY 6) Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion. ST 499917500 DRIVE PINION GAUGE ASSY
ST (A)
MT-00243
(A) Adjust the clearance to zero without shim.

+0 .1
(A)
(B) MT-00990
(A) Set number (B) Number for shim adjustment
7) The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by .) ST 499917500 DRIVE PINION GAUGE ASSY
3) Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
5MT-60

8) Select one to three shims in the following table for the value determined as described above, and take the shim(s) which thickness is closest to the said value.
Drive pinion shim Part number Thickness mm (in) 32295AA031 0.150 (0.0059) 32295AA041 0.175 (0.0069) 32295AA051 0.200 (0.0079) 32295AA061 0.225 (0.0089) 32295AA071 0.250 (0.0098) 32295AA081 0.275 (0.0108) 32295AA091 0.300 (0.0118) 32295AA101 0.500 (0.0197)
C: DISASSEMBLY
NOTE: Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly. 1) Flatten the tab of the lock nut. Remove the lock nut with ST1, ST2 and ST3. ST1 899884100 HOLDER ST2 498427100 STOPPER ST3 899988608 SOCKET WRENCH (27)
ST1
ST2
9) Install the front differential assembly. <Ref. to 5MT-69, INSTALLATION, Front Differential Assembly.> 10) Set the transmission main shaft assembly for single range and drive pinion shaft assembly in the install location. (When doing so, there will be no clearance between the two when moved all the way to the front). Inspect a suitable 1st-2nd, 3rd-4th and 5th shifter fork so that the coupling sleeve and reverse driven gear are positioned in the center of the synchronizing mechanism. <Ref. to 5MT-66, INSPECTION, Drive Pinion Shaft Assembly.> 11) Install the transmission case. <Ref. to 5MT-52, INSTALLATION, Transmission Case.> 12) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 13) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
ST3 MT-00244
2) Draw out the drive pinion from driven shaft. Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing and drive pinion collar.
(F) (G) (H) (E)
(A) (B) (D) (C) MT-00245
(A) (B) (C) (D) (E) (F) (G) (H)
Differential bevel gear sleeve Adjusting washer No. 1 (25 37.5 t) Thrust bearing (25 37.5 3) Adjusting washer No. 2 (25 37.5 4) Needle bearing (25 30 20) Drive pinion collar Needle bearing (30 37 23) Thrust bearing (33 50 3)
5MT-61

3) Remove the roller bearing and washer using ST and a press. NOTE: Do not reuse the roller bearing. ST 498077000 REMOVER
7) Remove the roller bearing and 3rd-4th driven gear using ST1 and ST2. ST1 499757002 INSTALLER ST2 899714110 REMOVER
ST1
ST2
ST MT-00246
MT-00249
4) Flatten the tab of the lock nut. Remove the lock nut using ST1 and ST2. ST1 499987300 SOCKET WRENCH (50) ST2 899884100 HOLDER
ST2 ST1
8) Remove the key. 9) Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
(D) (A)
(B)
(C)
MT-01633
MT-00247
5) Remove the 5th driven gear using ST. ST 499857000 5TH DRIVEN GEAR REMOVER
(A) (B) (C) (D)
2nd driven gear Inner baulk ring Synchro cone Outer baulk ring
ST
MT-00248
6) Remove the woodruff key.
5MT-62

10) Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing, gear and hub using ST1 and ST2.
(A) (D)
D: ASSEMBLY
1) Install the sleeve and gear & hub assembly by matching alignment marks. NOTE: After installation, make sure there is no significant gap at both sides of the ball detent.
(B) (C)
(D)
(C)
(B)
MT-01634
(A) (B) (C) (D)
1st driven gear Inner baulk ring Synchro cone Outer baulk ring
(A) MT-01639
NOTE: If necessary, use a new gear & hub assembly as a set, when replacing the gear or hub. Because these must engage at the specified point, avoid disassembly as much as possible. If it must be disassembled, mark the engaging point on the spline beforehand. ST1 499757002 INSTALLER ST2 899714110 REMOVER
(A) (B) (C) (D)
Ball detent 1st-2nd synchronizer hub Reverse driven gear There is no large clearance at this part.
NOTE: Use the new gear & hub assembly, if replacing the gear or hub.
(A) (B)
(C) ST1 (D) ST2 MT-00252 MT-00251
11) Remove the sub gear, washer and snap ring (outer) of the 1st driven gear. (Non-turbo model)
(A) (B) (C) (D)
1st gear side 2nd gear side Flush surface Stepped surface
2) Install the washer, snap ring (outer) and sub gear onto the 1st driven gear. (Non-turbo model)
5MT-63

3) Install the 1st driven gear, inner baulk ring, synchro cone and outer baulk ring, and gear & hub assembly onto driven shaft.
(A) (D)
5) Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert them onto driven shaft.
(D) (A)
(C)
(B)
MT-01634
(B)
(C)
MT-01633
(A) (B) (C) (D)
1st driven gear Inner baulk ring Synchro cone Outer baulk ring
(A) (B) (C) (D)
2nd driven gear Inner baulk ring Synchro cone Outer baulk ring
NOTE: Take care to install the gear & hub assembly in proper direction. Align the baulk ring and gear & hub assembly with the key groove. 4) Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Attach a cloth to the end of the driven shaft to prevent damage. When press fitting, align the oil holes of the shaft and bushing ST1 499277200 INSTALLER ST2 499587000 INSTALLER
6) After installing key on driven shaft, install the 3rd-4th driven gear using an ST and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Align the groove in baulk ring with the insert. ST 499277200 INSTALLER
ST
MT-00255
ST1
7) Install a set of roller bearings onto the driven shaft using ST and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER
ST2
MT-00253
ST
MT-00256
5MT-64

8) Position the woodruff key in groove of the rear of driven shaft. Install the 5th driven gear onto driven shaft using ST and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER
10) Install the roller bearing onto drive pinion. NOTE: When installing the roller bearing, note its directions (front and rear) because the knock pin hole of outer race is offset.
(A)
ST
(B)
MT-00260
MT-00257
9) Install the lock washer. Tighten the lock nuts to the specified torque using ST1 and ST2. ST1 499987300 SOCKET WRENCH (50) ST2 899884100 HOLDER Tightening torque: 260 Nm (26.5 kgf-m, 191.8 ft-lb)
ST2 ST1
(A) Roller bearing (B) Knock pin hole
11) Install the washer using ST1, ST2 and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 499277100 BUSHING 1-2 INSTALLER ST2 499277200 INSTALLER
ST2
ST1 (A) MT-01815
NOTE: Crimp the locknut in 2 locations. Using a spring scale, check that starting torque of the roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).
MT-00261
(A) Washer
12) Install the thrust bearing and needle bearing. Install the driven shaft assembly.
MT-00259
MT-00262
5MT-65

13) Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order. NOTE: Be careful to install the spacer in the proper direction.
(A) (B)
E: INSPECTION
Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully. 1) Bearing Replace the bearings in the following cases. When the bearing balls, outer races and inner races are broken or rusty. When the bearing is worn. When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is disassembled. In this case, because a preload is working on the bearing, its rotation feels like it is slightly dragging unlike other bearings.
(C) (D) (E) (F) (G) (H) MT-00263
(A) (B) (C) (D) (E) (F) (G) (H)
Driven shaft Drive pinion shaft Drive pinion collar Needle bearing (25 30 20) Adjusting washer No. 2 (25 36 4) Thrust bearing (25 37.5 3) Adjusting washer No. 1 (25 36 t) Differential bevel gear sleeve
(A)
(B) MT-00264
14) Adjust the thrust bearing preload. <Ref. to 5MT-67, THRUST BEARING PRELOAD, ADJUSTMENT, Drive Pinion Shaft Assembly.>
(A) Drive pinion shaft (B) Ball bearing
When the bearing has other problems. 2) Bushing (each gear) Replace the bushing in following cases. When the sliding surface is damaged or abnormally worn. When the inner wall is abnormally worn. 3) Gear Replace the bearings in the following cases. Replace gear with new part if its tooth surfaces are broken, damaged or excessively worn. Correct or replace if the cone that contacts the baulk ring is rough or damaged. Correct or replace if the inner surface or end face is damaged.
5MT-66

4) Baulk ring Replace the ring in following cases: When the inner surface and end face are damaged. When the ring inner surface is abnormally or partially worn down. If the gap between the end faces of the ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone. Clearance (A): 0.5 mm (0.020 in) or more
(A)
F: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) Select a suitable adjusting washer No. 1 to so that dimension (H) will be zero in a visual check. Position the washer (18.3 30 4) and lock washer (18 30 2) and install lock nut. (18 13.5)
MT-01674
(H)
(A) Measured value
When the contact surface of the synchronizer ring insert section is scratched or abnormally worn. 5) Ball detent Replace the ball detent if deformed, excessively worn or defective in any way.
(A)
MT-00267
2) Using the ST1, ST2 and ST3, tighten the new lock nut to the specified torque. ST1 899884100 HOLDER ST2 498427100 STOPPER ST3 899988608 SOCKET WRENCH (27) Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb)
ST1
MT-01640
ST2
(A) Ball detent
6) Oil seal Replace the oil seal if the lip is deformed, hardened, worn or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn or defective in any way.
ST3 MT-00268
5MT-67

3) After removing the ST2, measure the starting torque using torque driver. ST1 899884100 HOLDER ST3 899988608 SOCKET WRENCH (27) Starting torque: 0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ft-lb)
ST1
5) If the specified starting torque cannot be obtained by the selection of washer No. 1, select adjusting washer No. 2 from the list below. Repeat steps 1) through 4) to adjust starting torque.
ST3
(A) (B) MT-00270
MT-00269
(A) Adjusting washer No. 1 (B) Adjusting washer No. 2 Starting torque Low High Dimension H Small Large Adjusting washer No. 2 Select thicker one. Select thinner one.
4) If the starting torque is not within the specified limit, select new adjusting washer No. 1 and recheck starting torque.
Adjusting washer No. 2 Part number Thickness mm (in) 803025059 3.850 (0.1516) 803025054 4.000 (0.1575) 803025058 4.150 (0.1634)
(A) (B) MT-00270
(A) Adjusting washer No. 1 (B) Adjusting washer No. 2 Adjusting washer No. 1 Part number Thickness mm (in) 803025051 3.925 (0.1545) 803025052 3.950 (0.1555) 803025053 3.975 (0.1565) 803025054 4.000 (0.1575) 803025055 4.025 (0.1585) 803025056 4.050 (0.1594) 803025057 4.075 (0.1604)
6) Recheck that the starting torque is within the specified range, then crimp the lock nut at four positions.
5MT-68


A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove the transmission case. <Ref. to 5MT51, REMOVAL, Transmission Case.> 4) Remove the drive pinion shaft assembly. <Ref. to 5MT-60, REMOVAL, Drive Pinion Shaft Assembly.> 5) Remove the main shaft assembly for singlerange. <Ref. to 5MT-54, REMOVAL, Main Shaft Assembly for Single-Range.> 6) Remove the front differential assembly. NOTE: Do not confuse the right and left roller bearing outer races. Be careful not to damage the oil seal of retainer.
B: INSTALLATION
1) Install the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER 2) Install the bearing outer race to the transmission case. 3) Install the front differential assembly. NOTE: Be careful not to fold the sealing lip of oil seal.
MT-00162
MT-00162
7) Remove the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER
ST
4) Install the main shaft assembly for single-range. <Ref. to 5MT-54, INSTALLATION, Main Shaft Assembly for Single-Range.> 5) Install the drive pinion shaft assembly. <Ref. to 5MT-60, INSTALLATION, Drive Pinion Shaft Assembly.> 6) Install the transmission case. <Ref. to 5MT-52, INSTALLATION, Transmission Case.> 7) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 8) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
MT-00176
8) Remove the bearing outer race from the transmission case. ST 398527700 PULLER ASSY
5MT-69

C: DISASSEMBLY
1) Loosen the twelve bolts and remove hypoid driven gear.
3) Pull out the pinion shaft, and remove the differential bevel pinion, differential bevel gear and washer.
(D) (A) (C) (B) (B) (C) (D)
(A)
MT-00277
(A) (B) (C) (D)
Pinion shaft Differential bevel pinion Differential bevel gear Washer
4) Using the ST, remove the roller bearing. ST 899524100 PULLER SET
MT-00275
(A) Hypoid driven gear
ST
2) Drive out the straight pin from differential assembly toward hypoid driven gear side. ST 899904100 REMOVER
MT-00278
ST
MT-00276
5MT-70

2. SIDE RETAINER
D: ASSEMBLY
1) Install the differential bevel gear and differential bevel pinion together with washer, and insert the pinion shaft. NOTE: Face the chamfered side of washer toward gear.
MT-00279
2) Remove the oil seal. NOTE: Remove it by using flat tip screwdriver. Do not reuse the oil seal. Replace the oil seal with a new part.
(B)
(A)
(C) MT-00284
(A) Differential bevel pinion (B) Differential bevel gear (C) Pinion shaft
MT-01445
2) Measure the backlash between the differential bevel gear and differential bevel pinion. If backlash is not within specified value, install a suitable washer to adjust. <Ref. to 5MT-73, BEVEL PINION GEAR BACKLASH, INSPECTION, Front Differential Assembly.> NOTE: Be sure the pinion gear teeth contacts adjacent gear teeth during measurement. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0.13 0.18 mm (0.0051 0.0071 in)
ST2
ST1 MT-00285
5MT-71

3) Align the pinion shaft and differential case with each hole, and drive the straight pin into the holes from the hypoid driven gear using ST. NOTE: Lock the straight pin after installing. ST 899904100 REMOVER
5) Install the hypoid driven gear to the differential case using twelve bolts. Tightening torque: T: 62 Nm (6.3 kgf-m, 45.7 ft-lb)
(A)
(A) (C)
T (B) (B) MT-00286 MT-00993
(A) Hypoid driven gear (B) Differential case
(A) Pinion shaft (B) Differential case (C) Straight pin
2. SIDE RETAINER
1) Install a new oil seal. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
4) Install the roller bearing to differential case. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Be careful because the roller bearing outer races are used as a set. ST1 499277100 BUSHING 1-2 INSTALLER ST2 398497701 ADAPTER
ST
MT-00289 ST1
CAUTION: When press-fitting the oil seal to the side retainer, tap with a plastic hammer etc. to press in. Do not use a press. 2) Install a new O-ring.
MT-00287
ST2
NOTE: Do not stretch or damage the O-ring.
MT-00279
5MT-72

E: INSPECTION
Repair or replace the differential gear in the following cases. When the hypoid drive gear and drive pinion shaft tooth surfaces are damaged, excessively worn, or seized. When the roller bearing on the drive pinion shaft has a worn or damaged roller path. When there is damage, wear or seizure of the differential bevel pinion, differential bevel gear, washer, pinion shaft or straight pin. When the differential case has worn or damaged sliding surfaces.
(A)
1. BEVEL PINION GEAR BACKLASH

Measure the backlash between the differential bevel gear and differential bevel pinion. If backlash is not within specified value, install a suitable washer to adjust. <Ref. to 5MT-74, ADJUSTMENT, Front Differential Assembly.> ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0.13 0.18 mm (0.0051 0.0071 in)
ST2
(G) (E) (F) ST1 MT-00285 (E) (H) (B) (C) (G)
(F)
2. HYPOID GEAR BACKLASH

1) Set the ST1, ST2 and ST3. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface on the right corner, and check the backlash. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE ST3 498255400 PLATE 2) Install SUBARU genuine axle shafts to both sides, rotate in the inversion direction so that the gauge contacts the tooth surface, and read the dial gauge Part No. 38415AA100 Axle shaft Backlash 0.13 0.18 mm (0.0051 0.0071 in)
(D)
(I)
(H) MT-01074
(A) (B) (C) (D) (E) (F) (G) (H) (I)
Drive pinion shaft Hypoid driven gear Pinion shaft Straight pin Washer Differential bevel gear Differential bevel pinion Roller bearing Differential case
ST3
ST2
ST1
MT-00293
NOTE: If the backlash is outside the specified range, adjust it by turning the side retainer in the right side case.
5MT-73

3. TOOTH CONTACT OF HYPOID GEAR

Check tooth contact of hypoid gear as follows: Apply a thin uniform coat of red lead on both teeth surfaces on 3 or 4 teeth of the hypoid gear. Move the hypoid gear back and forth by turning the transmission main shaft until a definite contact pattern is developed on the hypoid gear, and judge whether face contact is correct. When the contact pattern is not correct, adjust the tooth contact. <Ref. to 5MT74, ADJUSTMENT, Front Differential Assembly.> Tooth contact is correct.
(A)
F: ADJUSTMENT
1) Disassemble the front differential assembly. <Ref. to 5MT-70, DISASSEMBLY, Front Differential Assembly.> 2) Select a different washer from the table and install.
Washer Part number 803038021 803038022 Thickness mm (in) 0.925 0.950 (0.0364 0.0374) 0.975 1.000 (0.0384 0.0394) 1.025 1.050 (0.0404 0.0413)
(D)
(B)
803038023
3) Adjust until the standard value is obtained. Backlash: Standard 0.13 0.18 mm (0.0051 0.0071 in)
(C)
MT-01402
(A) (B) (C) (D)
Toe Coast side Heel Drive side

Adjust the backlash by turning the side retainer in the RH side case. ST 18630AA010 WRENCH COMPL RETAINER
ST
MT-00176
NOTE: Each time side retainer rotates one tooth, backlash changes by 0.05 mm (0.0020 in).
0.05mm(0.0020 in)
MT-00296
5MT-74


1) Adjust until correct teeth contact is obtained. 2) Check tooth contact, and perform the adjustment as follows. Tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)
(A)
AT-00209
Corrective action: Loosen the side retainer to move the driven gear away from the drive pinion.
(B)
MT-01401
MT-01800
Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern
AT-00208
Corrective action: Tighten the side retainer to move the driven gear closer to the drive pinion.
AT-00210
Corrective action: Increase thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to the driven gear.
MT-01799
AT-00213
5MT-75

Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern
AT-00211
Corrective action: Reduce the thickness of the drive pinion shim according to the procedure for moving the drive pinion away from the driven gear.
AT-00212
5MT-76
Reverse Idler Gear

18.Reverse Idler Gear

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch neutral position switch. <Ref. to 5MT-35, REMOVAL, Switches and Harness.> 3) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the transmission case. <Ref. to 5MT51, REMOVAL, Transmission Case.> 5) Remove the drive pinion shaft assembly. <Ref. to 5MT-60, REMOVAL, Drive Pinion Shaft Assembly.> 6) Remove the main shaft assembly for singlerange. <Ref. to 5MT-54, REMOVAL, Main Shaft Assembly for Single-Range.> 7) Remove the front differential assembly. <Ref. to 5MT-69, REMOVAL, Front Differential Assembly.> 8) Remove the shifter forks and rods. <Ref. to 5MT79, REMOVAL, Shifter Fork and Rod.> 9) Pull out the straight pin, and remove the reverse idler gear shaft, washer, reverse idler gear and washer.
(E) (B) (F) (A) (C)
B: INSTALLATION
1) Install the reverse shifter lever, washer, reverse idler gear, washer and reverse idler gear shaft, and secure them with the straight pin. NOTE: Be sure to install the reverse idler gear shaft from rear side.
(E) (B) (F) (A) (C)
(D)
MT-01565
(A) (B) (C) (D) (E) (F)
Straight pin Reverse idler gear shaft Reverse idler gear Washer Washer Reverse shifter lever
(D)
MT-01565
(A) (B) (C) (D) (E) (F)
Straight pin Reverse idler gear shaft Reverse idler gear Washer Washer Reverse shifter lever
10) Remove the reverse shifter lever.
2) Check and adjust clearance between the reverse idler gear and the transmission case wall surface. <Ref. to 5MT-77, INSTALLATION, Reverse Idler Gear.> <Ref. to 5MT-78, ADJUSTMENT, Reverse Idler Gear.> 3) Install the shifter forks and rods. <Ref. to 5MT80, INSTALLATION, Shifter Fork and Rod.> 4) Install the front differential assembly. <Ref. to 5MT-69, INSTALLATION, Front Differential Assembly.> 5) Install the main shaft assembly for single-range. <Ref. to 5MT-54, INSTALLATION, Main Shaft Assembly for Single-Range.> 6) Install the drive pinion shaft assembly. <Ref. to 5MT-60, INSTALLATION, Drive Pinion Shaft Assembly.> 7) Install the transmission case. <Ref. to 5MT-52, INSTALLATION, Transmission Case.> 8) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 9) Install the back-up light switch neutral position switch. <Ref. to 5MT-35, INSTALLATION, Switches and Harness.> 10) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
5MT-77
Reverse Idler Gear

C: INSPECTION
1) Move the reverse shifter rod toward the reverse side. Check the clearance between the reverse idler gear and the timing case wall surface. If out of specification, select an appropriate reverse shifter lever and adjust. Clearance A: 6.0 7.5 mm (0.236 0.295 in)
D: ADJUSTMENT
1) Select the appropriate reverse shifter lever from the table below, and adjust until the clearance between the reverse idler gear and transmission case wall is within specification. Clearance A: 6.0 7.5 mm (0.236 0.295 in)
A A
MT-00305 MT-00305
A Measured value A Measured value Reverse shifter lever Mark Remarks 7 Far from case wall 8 Standard 9 Closer to case wall
2) After installing a suitable reverse shifter lever, shift into neutral. Check the clearance between the reverse idler gear and the timing case wall surface. If out of specification, select the appropriate washer and adjust. Clearance: 0 0.5 mm (0 0.020 in)
2) Select the appropriate washer from the table below, and adjust until the clearance between the reverse idler gear and transmission case wall is within specification. Clearance: 0 0.5 mm (0 0.020 in)
MT-00306
3) Check the reverse idler gear and shaft for damage. Replace if damaged.
MT-00306
Washer Part number 803020151 803020152 803020153 803020154 803020155 Thickness mm (in) 0.4 (0.016) 1.1 (0.043) 1.5 (0.059) 1.9 (0.075) 2.3 (0.091)
5MT-78
Shifter Fork and Rod

19.Shifter Fork and Rod

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the back-up light switch neutral position switch. <Ref. to 5MT-35, REMOVAL, Switches and Harness.> 3) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-38, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the transmission case. <Ref. to 5MT51, REMOVAL, Transmission Case.> 5) Remove the drive pinion shaft assembly. <Ref. to 5MT-60, REMOVAL, Drive Pinion Shaft Assembly.> 6) Remove the main shaft assembly for singlerange. <Ref. to 5MT-54, REMOVAL, Main Shaft Assembly for Single-Range.> 7) Remove the front differential assembly. <Ref. to 5MT-69, REMOVAL, Front Differential Assembly.> 8) Drive out the straight pin by tapping with the ST, and pull out the 5th shifter fork. ST 398791700 STRAIGHT PIN REMOVER 2
10) Drive out the straight pin by tapping with the ST, and pull out the 3rd 4th fork rod and shifter fork. NOTE: When removing the rod, keep other rods in neutral. Also, when pulling out the straight pin, remove it toward the inside of case so that it does not hit against the case. ST 398791700 STRAIGHT PIN REMOVER 2
(C)
(A)
(B)
MT-00994
(A) Straight pin (B) 3rd-4th fork rod (C) Shifter fork
11) Drive out the straight pin by tapping with the ST, and pull out the 1st 2nd fork rod and shifter fork. ST 398791700 STRAIGHT PIN REMOVER 2 12) Remove the snap ring (outer), and pull out the reverse fork rod from reverse fork rod arm. Then take out the ball, spring and interlock plunger from the rod. And then remove the rod. NOTE: When pulling out the reverse fork rod arm, be careful not to let the ball pop out of arm. 13) Remove the reverse shifter lever.
(B)
(A)
MT-00309
(A) Straight pin (B) 5th shifter fork
9) Remove the plugs, springs and check balls.
5MT-79

B: INSTALLATION
1) Install the reverse arm fork spring, ball and interlock plunger to the reverse fork rod arm. Insert the reverse fork rod into the hole of the reverse fork rod arm, and hold it with snap ring (outer) using ST. NOTE: Apply grease to plunger to prevent it from falling. ST 399411700 ACCENT BALL INSTALLER 2) Position the ball, spring and new gasket in the reverse fork rod hole on the left side of transmission case, and tighten the checking ball plug. 3) Install the 1st-2nd fork rod into 1st-2nd shifter fork through the hole on the rear of transmission case. 4) Align the holes in the rod and the fork, and drive the new straight pin into these holes using the ST. NOTE: Set other rods to neutral. Make sure the interlock plunger is on the 3rd-4th fork rod side. ST 398791700 STRAIGHT PIN REMOVER 2 5) Attach the interlock plunger on 3rd 4th fork rod. NOTE: Apply grease to plunger to prevent it from falling. 6) Attach the 3rd 4th fork rod into 3rd 4th shifter fork through the hole on the rear of transmission case. 7) Align the holes in the rod and the fork, and drive the new straight pin into these holes. NOTE: Set the reverse fork rod to neutral. Make sure the interlock plunger (before installation) is on the reverse fork rod side. ST 398791700 STRAIGHT PIN REMOVER 2 8) Install the 5th shifter fork onto the rear of reverse fork rod. Align the holes in the two parts and drive new straight pin into the specified place. ST 398791700 STRAIGHT PIN REMOVER 2
(B)
9) Position the balls, check ball springs and new gaskets into holes of the 3rd 4th fork rods and 1st 2nd fork rods, and install the plugs. Tightening torque: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
MT-00366
10) Install the front differential assembly. <Ref. to 5MT-69, INSTALLATION, Front Differential Assembly.> 11) Install the main shaft assembly for singlerange. <Ref. to 5MT-54, INSTALLATION, Main Shaft Assembly for Single-Range.> 12) Install the drive pinion shaft assembly. <Ref. to 5MT-60, INSTALLATION, Drive Pinion Shaft Assembly.> 13) Install the transmission case. <Ref. to 5MT-52, INSTALLATION, Transmission Case.> 14) Install the transfer case together with the extension case assembly. <Ref. to 5MT-38, INSTALLATION, Transfer Case and Extension Case Assembly.> 15) Install the back-up light switch neutral position switch. <Ref. to 5MT-35, INSTALLATION, Switches and Harness.> 16) Install the manual transmission assembly to the vehicle. <Ref. to 5MT-27, INSTALLATION, Manual Transmission Assembly.>
(A)
(C)
MT-00311
(A) 5th shifter fork (B) Reverse fork rod (C) Straight pin
5MT-80

C: INSPECTION
1) Check the fork and rod for damage. Replace if damaged. 2) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way. 3) Inspect the clearance between 1st, 2nd driven gear and reverse driven gear. If any clearance is not within specifications, replace the shifter fork as required. Clearance (a) and (b): 9.5 mm (0.374 in)
(A) (a) (B) (b) (C)
4) Inspect the clearance between the 3rd, 4th drive gear and the coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required. Clearance (a) and (b): 9.3 mm (0.366 in)
(a) (A) (B) (b) (C)
MT-00940
(a), (b) Measured value (A) 3rd drive gear (B) Coupling sleeve (C) 4th drive gear 3rd-4th shifter fork Mark Remarks Approaches 4th gear by 0.2 mm 1 (0.008 in). Standard Approaches 3rd gear by 0.2 mm 3 (0.008 in).
MT-01635
(a), (b) Measured value Part number (A) 1st driven gear (B) Reverse driven gear (C) 2nd driven gear 1st-2nd shifter fork Mark Remarks Approaches 1st gear by 0.2 mm 1 (0.008 in). Standard 3 Approaches 2nd gear by 0.2 mm (0.008 in). 32810AA061 32810AA071 32810AA101 Part number 32804AA060 32804AA070 32804AA080
5MT-81

5) Inspect the clearance between 5th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required. Clearance (a): 9.3 mm (0.366 in)
(A) (a) (B)
MT-01512
(a) Measured value (A) 5th drive gear (B) Coupling sleeve 5th shifter fork Mark Remarks Approaches 5th gear by 0.2 mm 7 (0.008 in). No mark Standard Moves away from 5th gear by 9 0.2 mm (0.008 in).
6) Inspect the rod end clearances (A) and (B). If any clearance is not within specifications, replace the rod or fork as required. Clearance (A): 3rd-4th 5th 0.5 1.3 mm (0.020 0.051 in) Clearance (B): 1st-2nd 3rd-4th 0.4 1.4 mm (0.016 0.055 in)
(A)
(B)
MT-00316
(A), (B) Measured value
5MT-82


A: INSPECTION
Symptom 1. Gears are difficult to intermesh. NOTE: The causes for difficulty in shifting gears can be classified into two kinds: One is a abnormal gear shift system and the other is abnormal transmission. However, if the operation is heavy and engagement of the gears is difficult, a defective clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear shift system and transmission. 2. Gear slip-out Gear slips out when coasting on rough road. Gear slips out during acceleration. Possible cause (a) Worn, damaged or burred chamfer at internal spline of sleeve and reverse driven gear (b) Worn, damaged or burred chamfer of gear spline (c) Worn or scratched bushings (d) Incorrect contact or wear between synchronizer ring and gear cone Replace. Corrective action
Replace. Replace. Repair or replace.
(a) Abnormal pitching stopper adjustment (b) Loose engine mounting bolts (c) Worn fork shifter, broken shifter fork rail spring (d) Worn or damaged ball bearing (e) Excessive clearance between splines of synchronizer hub and synchronizer sleeve (f) Synchronizer hub tooth step wear (g) Worn 1st driven gear and driven shaft (h) Worn 2nd driven gear and bushing (i) Worn 3rd drive gear and needle bearing (j) Worn 4th drive gear and needle bearing (k) Worn reverse idler gear and bushing
Adjust. Tighten or replace. Replace. Replace. Replace.
Replace. Replace. Replace. Replace. Replace. Replace.
3. Noise emitted from transmission NOTE: If a noise is heard when the vehicle is parked with its engine idling and if a noise ceases when the clutch is disengaged, it may be considered that the noise is coming from the transmission.
(a) Insufficient or improper lubrication Lubricate with specified oil or replace. (b) Worn or damaged gears and bearings Replace. NOTE: If the trouble is only wear of the tooth surfaces, merely a high roaring noise will occur at high speeds, but if any part is broken, rhythmical knocking sound will be heard even at low speeds.
5MT-83

2. DIFFERENTIAL
Symptoms 1. Broken differential (case, gear, bearing, etc.) NOTE: Noise will occur, and eventually the differential will not be able to operate due to broken pieces obstructing the gear revolution. Possible cause (a) Insufficient or improper oil Corrective action Disassemble the differential and replace broken components. At the same time check other components for any trouble, and replace if necessary. Readjust the preload and backlash of the bearing, and the contact surface of gear. Adjust. Adjust. Add recommended oil to the specified level. Do not use vehicle under severe operating conditions. Tighten. Lubricate. Check the tooth contact. Replace as a set. Readjust the bearing preload. Readjust the backlash of the hypoid driven gear to drive pinion, and check the tooth contact. Replace. Replace.
(b) Use of vehicle under severe conditions such as excessive load and improper use of the clutch (c) Improper adjustment of taper roller bearing (d) Improper adjustment of the drive pinion and the hypoid driven gear (e) Excessive backlash of a vehicle under severe operating conditions due to worn differential side gear, washer or differential pinion. (f) Loose hypoid driven gear tightening bolts (a) Insufficient oil (b) Improper adjustment of hypoid driven gear and drive pinion (c) Worn teeth of hypoid driven gear and drive pinion (d) Loose roller bearing
2. Differential and hypoid gear noises Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of trouble. However, noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the following four kinds of noises. Gear noise when driving: If noise increases as the vehicle speed increases, it may be due to insufficient gear oil, incorrect gear engagement, damaged gears, etc. Gear noise when coasting: Damaged gears due to misadjusted bearings and incorrect shim adjustment. Bearing noise when driving or coasting: Cracked, broken or damaged bearings Noise mainly when turning: Noise from differential side gear, differential pinion or differential pinion shaft, etc.
(e) Distorted hypoid driven gear or differential case (f) Worn washer and differential pinion shaft
5MT-84
General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND FRONT DIFFERENTIAL
Type 1st 2nd 3rd 4th 5th 6th Rev. Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio 6-forward speeds and 1-reverse 3.636 2.235 1.521 1.137 0.891 0.707 3.545 Hypoid 3.900 Helical 1.100 Hypoid 3.545 Straight bevel gear (Bevel pinion: 4, Bevel gear: 2) Straight bevel gear (Bevel pinion: 2, bevel gear: 2 and viscous LSD) GL-5 4.1 2 (4.3 US qt, 3.6 Imp qt)
Transmission gear ratio
Front reduction gear Rear reduction gear
Final Transfer Final
Front differential Center differential
Type and number of gear Type and number of gear
Transmission gear oil Transmission gear oil capacity
2. TRANSMISSION GEAR OIL

Recommended oil: GL-5 (75W-90) or equivalent
6MT-2
General Description
B: COMPONENT
1. CLUTCH HOUSING
(4) (3) (1) T2
(2) (9)
(5)
(10)
(7) T3 (8) T1 (11) (6) T4
MT-01809
(1) (2) (3) (4) (5) (6)
Oil level gauge Plug Pitching stopper bracket Clip Clutch housing Gasket
(7) (8) (9) (10) (11)
Oil seal Clutch release bearing guide Return spring bracket O-ring Drain plug
6MT-3
General Description
2. ADAPTER PLATE
T3 (2) (1)
(12) T1 T2
(3) (4) (5) (11) (6) (10) (9) (8) T2 (7)
T1 T3
(13)
T1 MT-01609
(1) (2) (3) (4) (5) (6)
Breather hose Transmission harness stay Check plug O-ring Check spring Plunger
(7) (8) (9) (10) (11) (12)
Check plug O-ring Check spring Check ball Oil guide A Oil guide B
(13)
Adapter plate
6MT-4
General Description
3. TRANSMISSION CASE
(2) T2 T3 (1) (10) (5) (10) (10) T2
(3) (7) (8) (4) (10) (9)
T1 (6) T1
T4
MT-01810
(1) (2) (3) (4) (5)
Pilot bolt Neutral switch Back-up light switch Adapter plate Transmission case
(6) (7) (8) (9) (10)
Harness bracket Ball Spring Plug Gasket
Tightening torque:Nm (kgf-m, ft-lb) T1: 16 (1.6, 11.8) T2: 32 (3.3, 23.6) T3: 34 (3.5, 25.1) T4: 41 (4.2, 30.2)
6MT-5
General Description
4. OIL PAN & OIL GUIDE

(10) (3)
(1)
(2)
(4) T3
T3
(7)
(11)
(5)
(6) T4 T2 (9)
T1
(8) MT-01811
(1) (2) (3) (4) (5) (6)
Transmission case Transfer bearing holder Oil guide G Oil guide H Oil pan Gasket
(7) (8) (9) (10) (11)
Oil guide F Oil guide D Oil guide E Oil guide C Drain plug
6MT-6
General Description
5. EXTENSION CASE AND CENTER DIFFERENTIAL
(5) (4) (3) (15) (16)
(17)
(2) (14) (1) T3
(18) (21) (10) (9) (7) (6) (11) (31) (25) (27) T1 (28) (29) (30) T2 (26) (8) (13) (12) (19) (20) (22) (23) (24)
MT-01817
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Taper roller bearing Transfer driven gear Taper roller bearing Shim Oil plate Center differential Shim Needle bearing Needle bearing Transfer drive gear Ball bearing (with flange) Snap ring
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Oil guide Extension Case Oil seal Oil seal Dust cover Snap ring Washer Bushing Spring Reverse check shaft Ball bearing Oil seal
(25) (26) (27) (28) (29) (30) (31)
Reverse check lever COMPL Straight pin Reverse check plug Spring Gasket Plug Plunger
6MT-7
General Description
6. SHIFTER FORK AND FORK ROD
(9) (8) (7) (1)
(10)
(15)
(1)
(6)
(18)
(14)
(1)
(5) (4) (3) (1) (2) (1) (1) (1) (13) (1) (20) (11) (1) (21) (1) (17) (1) (1) (22)
(12)
(16)
(19)
(23) (24)
MT-01735
(1) (2) (3) (4) (5) (6) (7) (8)
Spring pin Interlock arm Interlock block Reverse interlock block Interlock arm Striking rod Selector arm No. 2 Neutral set spring
(9) (10) (11) (12) (13) (14) (15) (16)
Washer Snap ring Reverse fork COMPL Reverse shifter arm Reverse fork rod Selector arm Shifter arm shaft 5th-6th fork rod
(17) (18) (19) (20) (21) (22) (23) (24)
5th-6th shifter arm 5th-6th fork COMPL 3rd-4th fork rod 3rd-4th shifter arm 1st-2nd shifter arm 3rd-4th fork COMPL 1st-2nd fork rod 1st-2nd fork COMPL
6MT-8
General Description
7. MAIN SHAFT ASSEMBLY
(13) (1) (9) (11) (10) (8) (7) (6) (5) (4) (3) (2) (22) (12)
(20) (28) (27) (21) (19) (24) (15) (14) (16) (17) (18) (23) (25) (26)
(29)
MT-01499
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Main shaft Needle bearing 3rd drive gear Inner baulk ring Synchro cone Outer baulk ring 3rd-4th sleeve 3rd-4th hub Shifting insert 4th baulk ring 4th gear
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
4th bushing Needle bearing 5th bushing Needle bearing 5th drive gear 5th baulk ring 5th-6th sleeve 5th-6th hub Shifting insert 6th baulk ring 6th drive gear
(23) (24) (25) (26) (27) (28) (29)
Needle bearing 6th bushing Taper roller bearing Snap ring Washer Washer Lock nut
6MT-9
General Description
8. DRIVE PINION AND DRIVE SHAFT ASSEMBLY
(7) (6) (5) (4) (3) (2)
T3
T1 (15) (24) (23) (22)
(14) (1) (12) (11) (13)
(10) (9)
(21) (20) (27) (8) (19) (18) (17) (16) (25) (26) T2
MT-01498
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Drive pinion shaft Taper roller bearing Shim Washer Lock nut Thrust bearing Needle bearing Driven shaft Key Needle bearing 1st driven gear 1st synchro ring ASSY
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
1st-2nd sleeve Shifting insert 1st-2nd hub Outer baulk ring Synchro cone Inner baulk ring 2nd driven gear Needle bearing 2nd bushing 3rd-4th driven gear 5th-6th driven gear Ball bearing
(25) (26) (27)
Lock nut Shim Collar
Tightening torque:Nm (kgf-m, ft-lb) T1: 285 (29.1, 210.2) * 265 (27.0, 195.4) T2: 570 (58.1, 420.4) * 530 (54.0, 390.9) T3: 54 (5.5, 39.8) * Tightening torque when using the ST
6MT-10
General Description
9. REVERSE IDLER GEAR ASSEMBLY
(21) (7) (6) (5)
(4) (3) T (2) (15) (1) (14) (21) (8) (18) (19) (10) (9) (11) (13) (20) (16) (17)
(12)
MT-01500
(1) (2) (3) (4) (5) (6) (7) (8)
Base COMPL Counter high and low washer Reverse idler gear No. 2 Needle bearing Reverse idler synchro set Reverse idler gear bushing Needle bearing Shifting insert
(9) (10) (11) (12) (13) (14) (15) (16)
Reverse coupling sleeve Reverse idler gear Spring Sub gear Friction plate Snap ring Counter high and low washer Snap ring
(17) (18) (19) (20) (21)
Reverse idler holder Spring pin Knock pin Washer Gasket
6MT-11
General Description
10.FRONT DIFFERENTIAL
(7) (1) (8)
(9) (10) (9)
(3) (11) (2) (9) (8) (7)
(4)
(3) (9) (5)
T2 (14) (3) (17)
(12) (14) (6) (12) (13) (16) T1 (15) T1 MT-01529 (11)
(1) (2) (3) (4) (5) (6) (7)
Drive pinion shaft Hypoid driven gear Pinion shaft Differential case RH Straight pin Differential case LH Washer
(8) (9) (10) (11) (12) (13) (14)
Differential bevel gear Differential bevel pinion Pinion shaft joint Roller bearing Oil seal Differential side retainer RH O-ring
(15) (16) (17)
Retainer lock plate RH Retainer lock plate LH Differential side retainer LH
6MT-12
General Description
(4)
(6)
(3) T4 (2) (5)
T6 (1) T3 (8) T2 (12)
(3) (10) (2) (7) T2 (11) (9)
T5 T1
T7 T5
MT-01555
(1) (2) (3) (4) (5) (6)
Pitching stopper Spacer Lower cushion rubber Front plate Transmission cushion rubber Rear crossmember
(7) (8) (9) (10) (11) (12)
Upper cushion rubber Center crossmember Rear plate Front crossmember Dynamic damper Upper cushion rubber
Tightening torque:Nm (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: 35 (3.6, 25.8) T3: 50 (5.1, 36.9) T4: 58 (5.9, 42.8) T5: 70 (7.1, 51.6) T6: 75 (7.6, 55.3) T7: 140 (14.3, 103.3)
6MT-13
General Description
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. When disassembling the case and other light alloy parts, disassemble by using a plastic hammer. Do not pry apart with screwdrivers or other tools. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine transmission gear oil, grease or the equivalent. Do not mix transmission gear oil, grease etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Apply transmission gear oil onto sliding or revolving surfaces before installation. Replace deformed or damaged snap rings with new parts. Before installing O-rings or oil seals, apply sufficient amount of transmission gear oil to avoid damage and deformation. Be careful not to incorrectly install or fail to install O-rings, snap rings and other parts. Before securing a part on a vise, place cushioning materials such as wood blocks, aluminum plates, or waste cloth between the part and the vise. Avoid damaging the mating surface of the case. Before applying liquid gasket, completely remove the old liquid gasket.
6MT-14
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 398791700 TOOL NAME REMOVER REMARKS Used for removing and installing the spring pin (6 mm).
ST-398791700
399527700
(3) (2) (1)
PULLER SET
Used for removing and installing the roller bearing (Differential). (1) BOLT (899521412) (2) PULLER (399527702) (3) HOLDER (399527703) (4) ADAPTER (398497701) (5) BOLT (899520107) (6) NUT (021008000)
(4)
(5)
(6) ST-399527700
498515700
REMOVER
Used for removing the roller bearing of the drive pinion shaft.
ST-498515700
498247001
MAGNET BASE
Used for measuring backlash between the side gear, pinion, and hypoid gear. Used with the DIAL GAUGE (498247100).
ST-498247001
6MT-15
General Description
ILLUSTRATION TOOL NUMBER 498247100 TOOL NAME DIAL GAUGE REMARKS Used for measuring backlash between the side gear, pinion, and hypoid gear. Used together with MAGNET BASE (498247001).
ST-498247100
498077000
REMOVER
ST-498077000
899858600
REMOVER
Used for removing the roller bearing.
ST-899858600
499757002
INSTALLER
Used for installing the bearing cone of the transfer driven gear (extension core side).
ST-499757002
18630AA010
Used for removing and installing the differential side retainer RH. WRENCH ASSEMBLY (499787000) can also be used.
ST18630AA010
6MT-16
General Description
ILLUSTRATION TOOL NUMBER 499877000 TOOL NAME RACE 4-5 INSTALLER REMARKS Used for disassembling the driven shaft and transfer driven gear.
ST-499877000
899864100
REMOVER
Used for removing the transmission main shaft and drive pinion parts.
ST-899864100
498057300
INSTALLER
ST-498057300
498255400
PLATE
Used for measuring backlash.
ST-498255400
41099AA010
ENGINE SUPPORT BRACKET
ST41099AA010
6MT-17
General Description
ILLUSTRATION TOOL NUMBER 41099AA020 TOOL NAME ENGINE SUPPORT REMARKS Used for supporting engine.
ST41099AA020
398527700
PULLER ASSY
Used for removing the extension case oil seal and the front side retainer bearing outer race.
ST-398527700
398643600
GAUGE
Used for measuring the total end play, extension end play and drive pinion height.
ST-398643600
398177700
INSTALLER
Used for assembling the main shaft.
ST-398177700
399893600
PLIER
Used for removing and installing the neutral set spring. Used together with the CLAW (18756AA000).
ST-399893600
6MT-18
General Description
ILLUSTRATION TOOL NUMBER 18756AA000 TOOL NAME CLAW REMARKS Used for removing and installing the neutral set spring. Used together with PLIER (399893600).
ST18756AA000
499247400
INSTALLER
Used for installing the ball bearing of the transfer drive gear.
ST-499247400
398497701
SEAT
Used for installing the ball bearing of the transfer drive gear.
ST-398497701
398437700
INSTALLER
Used for installing the front differential side bearing.
ST-398437700
18632AA000
STAND ASSY
Used for disassembling and assembling the transmission.
ST18632AA000
6MT-19
General Description
ILLUSTRATION TOOL NUMBER 18671AA000 TOOL NAME OIL SEAL GUIDE REMARKS Used for installing the oil seal to the reverse check. Used with INSTALLER (18657AA010).
ST18671AA000
18657AA010
INSTALLER
Used for installing the oil seal to the reverse check. Used with OIL SEAL GUIDE (18671AA000).
ST18657AA010
18657AA000
INSTALLER
Used for installing the oil seal to the shift rod.
ST18657AA000
18758AA000
PULLER
Used for removing the extension taper roller bearing outer race.
ST18758AA000
18831AA000
GAUGE
Used for measuring the extension taper roller bearing.
ST18831AA000
6MT-20
General Description
ILLUSTRATION TOOL NUMBER 18631AA000 TOOL NAME HANDLE REMARKS Used for measuring the front differential backlash.
ST18631AA000
18754AA000
REMOVER
Used to remove parts of the driven gear.
ST18754AA000
18757AA000
STRAIGHT PIN REMOVER
Used for installing the reverse idler gear.
ST18757AA000
18665AA000
HOLDER
Used for removing and installing the main shaft lock nut. Used together with the BASE (18664AA000).
ST18665AA000
18666AA000
HOLDER
Used for removing and installing the driven shaft lock nut. Used together with the BASE (18664AA000).
ST18666AA000
6MT-21
General Description
ILLUSTRATION TOOL NUMBER 18667AA000 TOOL NAME HOLDER REMARKS Used for removing and installing the drive pinion shaft lock nut. Used together with the BASE (18664AA000).
ST18667AA000
18664AA000
BASE
Used for removing and installing the main shaft lock nut. Used for removing and installing the drive pinion shaft lock nut. Used for removing and installing the driven shaft lock nut.
ST18664AA000
18722AA010
REMOVER
Used for disassembling the main shaft.
ST18722AA010
18651AA000
INSTALLER
Used for assembling the main shaft.
ST18651AA000
18852AA000
TORQUE WRENCH
Used to tighten the main shaft lock nut. Used to tighten the drive pinion shaft lock nut. Used to tighten the driven shaft lock nut.
ST18852AA000
6MT-22
General Description
ILLUSTRATION TOOL NUMBER 18668AA000 TOOL NAME PUNCH REMARKS Used to crimp the main shaft lock nut.
ST18668AA000
18669AA000
PUNCH
Used to crimp the driven shaft lock nut.
ST18669AA000
18670AA000
PUNCH
Used to crimp the drive pinion shaft lock nut.
ST18670AA000
18620AA000
ADAPTER WRENCH
Used for removing and installing the driven gear shaft lock nut.
ST18620AA000
18621AA000
ADAPTER WRENCH
Used for removing and installing the drive pinion shaft lock nut.
ST18621AA000
6MT-23
General Description
ILLUSTRATION TOOL NUMBER 18723AA000 TOOL NAME REMOVER REMARKS Used for disassembling the driven shaft.
ST18723AA000
18630AA000
WRENCH ASSY
Used for removing and installing the differential side retainer LH.
ST18630AA000
18672AA000
GUIDE CLIP
Used for installing the reverse idler snap ring.
ST18672AA000
18720AA000
REMOVER
Used for disassembling the main shaft.
ST18720AA000
18654AA000
INSTALLER
Used for assembling the driven shaft.
ST18654AA000
6MT-24
General Description
ILLUSTRATION TOOL NUMBER 18663AA000 TOOL NAME SOCKET REMARKS Used for removing and installing the transfer bearing holder.
ST18663AA000
18853AA000
HEIGHT GAUGE
Used for selecting the shift rod.
ST18853AA000
18760AA000
CLAW
Used for removing the front side retainer bearing outer race. Used together with PULLER ASSY (398527700).
ST18760AA000
18675AA000
ST18675AA000
28399SA010
OIL SEAL PROTECTOR
Used for protecting oil seal when installing front drive shaft.
ST28399SA010
6MT-25
General Description
ILLUSTRATION TOOL NUMBER 18657AA020 TOOL NAME OIL SEAL INSTALLER REMARKS Used for installing the oil seal.
ST18657AA020
18270KA020
SOCKET (E20)
Used for removing and installing the hypoid driven gear.
ST18270KA020
2. GENERAL TOOL
TOOL NAME Circuit tester TORX bit T70 Depth gauge REMARKS Used for measuring resistance, voltage and current. Used for removing and installing transmission gear oil drain plug. Used for measuring the transmission end play.
6MT-26

2. Transmission Gear Oil

A: INSPECTION
1) Park the vehicle on a level surface. 2) Turn the ignition switch to OFF, and wait until the engine cools. 3) Remove the oil level gauge and wipe it clean. 4) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted in the proper direction. 5) Pull out the oil level gauge again, and check the oil level. If it is at the lower level or less, add oil through the oil level gauge hole to bring the level up to the upper level.
(A)
B: REPLACEMENT
1) Pull out the oil level gauge. 2) Lift up the vehicle. 3) Drain transmission gear oil completely. CAUTION: Immediately after the engine has been running, the transmission gear oil is hot. Be careful not to burn yourself. Be careful not to spill the transmission gear oil on exhaust pipe to prevent it from emitting smoke or causing fires. If transmission gear oil is spilled on the exhaust pipe, wipe it off completely. NOTE: Tighten the drain plug of the transmission gear oil after draining the transmission gear oil. Be sure to use a new gasket. Use TORX bit T70 to remove and install the drain plug on clutch housing side. Tightening torque: Oil pan side 50 Nm (5.1 kgf-m, 36.9 ft-lb) Clutch housing side 70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A)
(B) (C)
MT-00449
(A)
(B)
MT-01549
(A) Drain plug (Oil pan side) (B) Drain plug (clutch housing side)
4) Lower the vehicle. 5) Pour transmission gear oil through the gauge hole. Recommended gear oil GL-5 (75W-909) or equivalent Transmission gear oil capacity 4.1 2 (4.3 US qt, 3.6 Imp qt) 6) Check the level of the transmission gear oil. NOTE: Keep the transmission gear oil level to be between the range marked on the level gauge.
6MT-27
Oil Seal
3. Oil Seal
A: INSPECTION
Inspect for oil leakage from the oil seal. If there is any deformation, hardening, wear or other malfunctions of the oil seal, perform the following: Replace the oil seal. Inspect the propeller shaft.
B: REPLACEMENT
1) Clean the transmission exterior. 2) Drain transmission gear oil completely. <Ref. to 6MT-27, REPLACEMENT, Transmission Gear Oil.> 3) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 4) Remove the heat shield cover. (If equipped) 5) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 6) Remove the oil seal using ST. ST 398527700 PULLER ASSY
(A) ST
MT-00451
(A) Oil seal
7) Using the ST, install the oil seal. ST 498057300 INSTALLER
MT-00099
8) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 9) Install the heat shield cover. (If equipped) 10) Install the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 11) Pour in the transmission gear oil and check the oil level. <Ref. to 6MT-27, REPLACEMENT, Transmission Gear Oil.>
6MT-28

4. Differential Side Retainer Oil Seal

A: INSPECTION
Check that there is no oil leaking from the differential side retainer oil seal. If there is oil leakage, perform the following procedures. Replace the oil seal. Check the front drive shaft.
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the front exhaust pipe and center exhaust pipe. <Ref. to EX(H4DOTC)-5, REMOVAL, Front Exhaust Pipe.> 3) Drain transmission gear oil completely. <Ref. to 6MT-27, REPLACEMENT, Transmission Gear Oil.> 4) Separate the front drive shaft from the transmission. <Ref. to DS-22, REMOVAL, Front Drive Shaft.> 5) Remove the differential side retainer oil seal by using a flat tip screwdriver or similar tools. 6) Using the ST, install the differential side retainer oil seal by lightly tapping with a hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER 7) Apply transmission gear oil to the oil seal lips. 8) Set the ST to the side retainer. ST 28399SA010 OIL SEAL PROTECTOR 9) Install the front drive shaft into the transmission. NOTE: Replace the circlip of drive shaft with a new part. 10) Install the front drive shaft into transmission, remove the ST and insert the drive shaft securely. ST 28399SA010 OIL SEAL PROTECTOR 11) Install the front exhaust pipe and the center exhaust pipe. <Ref. to EX(H4DOTC)-6, INSTALLATION, Front Exhaust Pipe.> 12) Lower the vehicle. 13) Fill with transmission gear oil through the oil level gauge hole. Recommended gear oil: GL-5 (75W-90) or equivalent Transmission gear oil capacity: 4.1 2 (4.3 US qt, 3.6 Imp qt) 14) Check the level of the transmission gear oil. <Ref. to 6MT-27, INSPECTION, Transmission Gear Oil.>
6MT-29

5. Transmission Mounting System

A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from the battery. 2) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 3) Remove the pitching stopper.
B: INSTALLATION
1. PITCHING STOPPER
T1
T2 MT-01560
MT-01559

1) Disconnect the ground cable from the battery. 2) Lift up the vehicle. 3) Remove the center exhaust pipe. <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 4) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 5) Remove the heat shield cover. (If equipped) 6) Set the transmission jack under the transmission body. CAUTION: Always support the transmission case with a transmission jack. 7) Remove the front and rear crossmembers.
2) Install the intercooler. <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.> 3) Connect the ground cable to battery.

1) Install the transmission cushion rubber. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft-lb) 2) Install the front crossmember and rear crossmember. Tightening torque: T1: 75 Nm (7.6 kgf-m, 55.3 ft-lb) T2: 140 Nm (14.3 kgf-m, 103.3 ft-lb)
T1
T1
T2
T2
MT-01265
MT-01264
8) Remove the transmission cushion rubber.
3) Remove the transmission jack. 4) Install the heat shield cover. (If equipped) 5) Install the center exhaust pipe. <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> 6) Install the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.>
6MT-30

C: INSPECTION
Perform the following inspection procedures and repair or replace faulty parts.
1. PITCHING STOPPER
Check the pitching stopper for bends or damage. Check that the rubber is not stiff, cracked or otherwise damaged.

Check crossmember for bends or damage. Check that the cushion rubber is not stiff, cracked, or otherwise damaged.
6MT-31

6. Manual Transmission Assembly

A: REMOVAL
1) Set the vehicle on a lift. Open the front hood, and support it with the stay. NOTE: Set the hood stay into the specified hole. 2) Disconnect the ground cable from the battery. 3) Remove the collector cover. 4) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 5) Remove the front wheels. 6) Disconnect the following harness connectors, and then remove the engine hanger rear.
(C) (B)
8) Remove the starter assembly. <Ref. to SC(H4SO)-6, REMOVAL, Starter.> 9) Remove the operating cylinder from the transmission. NOTE: Hang the removed operating cylinder with a piece of wire.
CL-00445
10) Remove the pitching stopper and pitching stopper bracket. 11) Set the ST. ST1 41099AA010 ENGINE SUPPORT BRACKET ST2 41099AA020 ENGINE SUPPORT
MT-01540 ST2
(A)
(A) Neutral position switch backup light switch connector (B) Rear oxygen sensor connector (C) Pitching stopper
ST1
7) Disconnect the ground cable on the upper side of the transmission case and body.
MT-01526
MT-01266
12) Remove the clutch release shaft. (1) Remove the plug using a hexagon wrench. (2) Attach a 6 mm (0.24 in) bolt to the release shaft, and pull out the release shaft. (3) Lift the release fork, and remove from the claw of the release bearing. Pull the release fork to the engine side, and make it so that it moves freely. 13) Lift up the vehicle. 14) Remove the center exhaust pipe. <Ref. to EX(H4DOTC)-7, REMOVAL, Center Exhaust Pipe.> 15) Remove the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> CAUTION: When removing the exhaust pipes, be careful each exhaust pipe does not drop out.
MT-01267
6MT-32

16) Remove the bolts which hold upper side of transmission to engine.
23) Move the transmission to the right side of the vehicle, and remove the joint COMPL, stay bolts and reverse check cable. NOTE: If the transmission is not moved aside, the joint COMPL and stay bolts may contact the body and cause damage.
(C) (A)
MT-01524
17) Remove the heat shield cover. (If equipped) 18) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 19) Remove the front stabilizer link.
(B)
MT-00886
(A) Joint COMPL bolt (B) Stay bolt (C) Reverse check cable
24) Tighten the turnbuckle of the ST to tilt the engine assembly towards the back.
FS-00117
20) Remove the ball joint of front arm from the housing.
MT-00463
25) Remove the bolts and nuts holding the bottom of transmission to the engine, and remove the transmission from the vehicle.
FS-00106
21) Remove the front drive shaft. <Ref. to DS-22, REMOVAL, Front Drive Shaft.> 22) Set the transmission jack under the transmission, and remove the front crossmember and rear crossmember.
NOTE: During removal, be careful not to hit the transmission against the body when pulling towards the rear. The clutch pipe and breather pipe may interfere with each other. Remove carefully.
MT-01090 MT-01264
6MT-33

B: INSTALLATION
1) Set the release fork, release bearing and release shaft to the transmission. <Ref. to CL-19, INSTALLATION, Release Bearing and Lever.> 2) Replace the front differential side retainer oil seal. (1) Remove the oil seal by using flat tip screwdriver etc. (2) Apply gear oil to the lip of new oil seals. (3) Install a new oil seal using ST. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Be sure to replace the differential side oil seal after the procedure of removing front drive shaft from transmission. 3) Loosen the turnbuckle of ST to return the engine to its original position.
6) Move the transmission to the right side of the vehicle, and attach the joint COMPL, stay bolts and reverse check cable. Tightening torque: T1: 11.8 Nm (1.2 kgf-m, 8.7 ft-lb) T2: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
(A) T1 T2
MT-00465
(A) Reverse check cable
T1
MT-01527
4) Install the transmission. 5) Tighten the bolts and nuts which hold the lower side of the transmission to the engine. NOTE: Make sure that the main shaft spline is completely inserted. Make sure that the rear end of the engine is set low. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2 T2
T1
MT-01265
8) Tighten the bolts which the hold upper side of the transmission to the engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
MT-00464
MT-01524
6MT-34

9) Make sure that the release bearing is completely inserted. NOTE: Push the release fork towards the operating cylinder side until a clicking sound is heard. Pull the release fork towards the engine side. If the release fork is not in contact with the case, the setting is complete. Confirm that the boot cover is set securely.
13) Install the starter assembly. <Ref. to SC(H4SO)-6, INSTALLATION, Starter.> 14) Attach the ground cable to the transmission and body.
MT-01266
MT-00467
10) Install the pitching stopper bracket. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb) 11) Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
MT-01267
15) Connect the following harness connectors, then attach the engine hanger rear.
(C) (B)
T1
T2 MT-01560
(A)
MT-01540
12) Install the clutch operating cylinder. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb) NOTE: Check that the clutch hose is routed properly.
(A) Neutral position switch backup light switch connector (B) Rear oxygen sensor connector (C) Pitching stopper
16) Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR 17) Install the front drive shaft into the transmission. NOTE: Replace the circlip of drive shaft with a new part. 18) Install the front drive shaft into transmission, remove the ST and insert the drive shaft securely. ST 28399SA010 OIL SEAL PROTECTOR
CL-00445
6MT-35

19) Install the ball joint of the front arm. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
FS-00106
20) Install the front stabilizer link. Tightening torque: 45 Nm (4.6 kgf-m, 33.2 ft-lb) NOTE: Use a new self-locking nut.
FS-00117
21) Install the heat shield cover. (If equipped) 22) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 23) Install the rear exhaust pipe and muffler. <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 24) Install the center exhaust pipe. <Ref. to EX(H4DOTC)-9, INSTALLATION, Center Exhaust Pipe.> 25) Fill the transmission gear oil. <Ref. to 6MT-27, REPLACEMENT, Transmission Gear Oil.> 26) Install the intercooler. <Ref. to IN(H4DOTC)13, INSTALLATION, Intercooler.> 27) Install the collector cover. 28) Connect the ground cable to battery.
6MT-36

7. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from the transmission. 2) Attach the transmission to the ST. ST 18632AA000 STAND ASSY
ST
ST
ST MT-00468
3) Apply oil to rotating parts before assembly. 4) When reusing disassembled parts, reinstall in the original positions and directions. 5) Gaskets, lock washers and lock nuts must be replaced with new parts. 6) Apply liquid gasket to the specified areas to prevent leakage.
6MT-37
Air Breather Hose

8. Air Breather Hose

A: REMOVAL
Disconnect the air breather hose.
MT-01091
B: INSTALLATION
Connect the air breather hose.
MT-01091
C: INSPECTION
6MT-38
Back-up Light Switch

9. Back-up Light Switch

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Disconnect the back-up light switch connector.
B: INSTALLATION
1) Install the back-up light switch. NOTE: Use a new gasket. Tightening torque: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
(A) (B)
(A)
(C)
(C)
(B)
MT-00471
MT-00472
(A) Back-up light switch connector (Gray) (B) Neutral position switch connector (Brown) (C) Clip
(A) Back-up light switch (B) Neutral position switch
2) Connect the back-up light switch connector. 3) Disconnect the back-up light switch.
(A) (B) (A) (C)
(C)
(B) MT-00472
MT-00471
6MT-39
Back-up Light Switch

C: INSPECTION
1) Disconnect the ground cable from the battery. 2) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 3) Disconnect the transmission harness and chassis harness.
(A)
MT-01812
(A) Transmission connector
4) Measure the resistance between the back-up light switch terminals. If it is not within the specification, replace the back-up light switch.
Gear shift position Back position Other positions Terminal No. 2 and 4 Standard Less than 1 : 1 M: or more
2 1 4 3
MT-00474
6MT-40
Neutral Position Switch

10.Neutral Position Switch

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Disconnect the connector and clip of the neutral position switch.
B: INSTALLATION
1) Install the neutral position switch. NOTE: Use a new gasket. Tightening torque: 32 Nm (3.3 kgf-m, 23.6 ft-lb)
(A) (B)
(A)
(C)
(C)
MT-00472 (B) MT-00471
2) Connect the connector and clip of the neutral position switch.
3) Remove the neutral position switch.

(A) (B) (A) (C)
(C)
(B) MT-00472
MT-00471
6MT-41
Neutral Position Switch

C: INSPECTION
1) Disconnect the ground cable from the battery. 2) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 3) Disconnect the transmission harness and chassis harness.
(A)
MT-01812
(A) Transmission connector
4) Measure the resistance between neutral position switch terminals. If not within the standard values, replace the neutral position switch.
Gear shift position Neutral position Other positions Terminal No. 1 and 3 Standard 1 M: or more Less than 1 :
2 1 4 3
MT-01089
6MT-42
Extension Case
11.Extension Case
A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the extension case.
B: INSTALLATION
1) Select the thrust washer of the transfer driven gear, and attach to the extension case. <Ref. to 6MT-46, ADJUSTMENT, Extension Case.> 2) Apply a thin coat of oil to the outer surface of the bearing cone, and attach to the extension case. 3) Select the thrust washer of the transfer drive gear, and attach to the center differential. 4) Apply liquid gasket to the transmission case. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
MT-00475
4) Remove any remaining liquid gasket from the extension case and transmission case.
MT-00476
5) Install the extension case. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb)
MT-00475
6MT-43
Extension Case
C: DISASSEMBLY
1) Remove the transfer drive gear. <Ref. to 6MT53, REMOVAL, Transfer Drive Gear.> 2) Remove the oil guide.
6) Remove the shifter arm oil seal.
(A) MT-00481
(A) Oil seal

MT-00477
3) Remove the shift bracket.
7) Remove the reverse check system. <Ref. to 6MT-50, REMOVAL, Reverse Check System.> 8) Remove the extension oil seal. <Ref. to 6MT-28, REPLACEMENT, Oil Seal.>
MT-00478
4) Remove the bearing cone using the ST. ST 18758AA000 PULLER

(A) ST
MT-00479
(A) Bearing cone
5) Remove the thrust washer and oil plate.

(B) (A)
MT-00480
(A) Thrust washer (B) Oil plate
6MT-44
Extension Case
D: ASSEMBLY
1) Install the reverse check system. <Ref. to 6MT51, INSTALLATION, Reverse Check System.> 2) Install the extension case oil seal. <Ref. to 6MT28, REPLACEMENT, Oil Seal.> 3) Install a shifter arm oil seal using the ST. ST1 18657AA000 INSTALLER ST2 18671AA000 OIL SEAL GUIDE
E: INSPECTION
1) Check to make sure there is no damage or cracks on the extension case. If damage or cracking is found, replace the extension case. 2) Inspect for oil leaks at the extension case and transmission case oil seals and mating surfaces. If there are oil leaks, replace the oil seal and liquid gasket.
ST1
(A)
ST2 MT-00482
(A) Oil seal
4) Install the oil plate.
MT-00483
5) Select the thrust washer of the bearing, and attach to the extension case. <Ref. to 6MT-46, ADJUSTMENT, Extension Case.> 6) Apply a thin coat of oil to the outer surface of the bearing cone, and attach to the extension case. 7) Install the shift bracket. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00478
8) Attach the oil guide and the transfer driven gear. <Ref. to 6MT-53, INSTALLATION, Transfer Drive Gear.>
6MT-45
Extension Case
F: ADJUSTMENT
1. TRANSFER DRIVEN GEAR BEARING THRUST WASHER ADJUSTMENT
1) Remove the bearing cone from the extension case using the ST. ST 18758AA000 PULLER
(A) ST
5) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 6) Remove the oil guides G and H.
(A) (B)
MT-01728
(A) Oil guide G (B) Oil guide H

MT-00479
(A) Bearing cone
7) Remove the snap ring and flat washer from the selector arm area.
2) Remove the thrust washer. 3) Measure depth Z between the extension case end area and bearing cone contact area. ST 398643600 GAUGE NOTE: When measuring depth Z, subtract the thickness of the ST [15 mm (0.59 in)] from the measured value.
(A) Snap ring (B) Flat washer
ST (A) (B) MT-01616
8) Using an ST, remove the neutral set spring and support. ST1 18756AA000 CLAW ST2 399893600 PLIER
ST ST2 (A)
Z ST1 MT-01092
MT-00484
(A) 15 mm (0.59 in)
4) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.>
6MT-46
Extension Case
9) Lift the striking rod, and remove the spring pin.

(A)
14) Measure depth Y between the end of the ST and the bearing cone. ST 18831AA000 GAUGE
ST
(B)
MT-01307
(A) Striking rod (B) Spring pin
10) Remove the selector arm No. 2 and the shifter arm.
(A) (B)
MT-00490
MT-01618
(A) Selector arm No. 2 (B) Shifter arm
15) Using the following calculation, calculate the transfer driven gear bearing thrust washer value t. t = Z (100 Y) {0.02 0.11 mm (0.0008 0.0043 in)}
t mm (in) Y mm (in) Z mm (in) 0.02 0.11 mm (0.0008 0.0043 in) 100 mm (3.94 in) Transfer driven gear bearing thrust washer thickness Depth between the end of the ST and the bearing cone. Depth between the end of the extension case and the bearing cone contact area. Standard clearance between the thrust washer and taper roller bearing Height of ST
11) Attach the bearing cone to the transfer driven gear. 12) Set the ST. ST 18831AA000 GAUGE
ST
MT-00489
13) Turn the transfer driven gear 10 or more times to seat the bearing properly.
6MT-47
Extension Case
16) Refer to the calculated value t to select the closest thrust washer from the following table. Standard clearance between the thrust washer and taper roller bearing 0.02 0.11 mm (0.0008 0.0043 in)
Thrust washer (50 61 t) Part number Thickness t mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217) 803050062 0.60 (0.0236) 803050063 0.65 (0.0256) 803050064 0.70 (0.0276) 803050065 0.75 (0.0295) 803050066 0.80 (0.0315) 803050067 0.85 (0.0335) 803050068 0.90 (0.0354) 803050069 0.95 (0.0374) 803050070 1.00 (0.0394) 803050071 1.05 (0.0413) 803050072 1.10 (0.0433) 803050073 1.15 (0.0453) 803050074 1.20 (0.0472) 803050075 1.25 (0.0492) 803050076 1.30 (0.0512) 803050077 1.35 (0.0531) 803050078 1.40 (0.0551) 803050079 1.45 (0.0570)
19) Using the ST, install the neutral set spring and support. ST1 18756AA000 CLAW ST2 399893600 PLIER
ST2
ST1 MT-01092
20) Install the flat washer and snap ring to the selector arm area.
(A) (B) MT-01616
17) Install the selector arm No. 2 and the shifter arm.
(A) (B)
21) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.>
MT-01618
18) Install a new spring pin.
6MT-48
Extension Case
2. TRANSFER DRIVE GEAR THRUST WASHER SELECTION

1) Measure height Z between the transmission case end area and ST. ST 398643600 GAUGE
4) Refer to the calculated value t to select the closest thrust washer from the following table. Standard clearance between the thrust washer and transfer drive gear 0.45 0.65 mm (0.018 0.026 in)
Thrust washer (36.3 52 t) Part number Thickness mm (in) 803036070 0.80 (0.0315) 803036071 0.95 (0.0374) 803036072 1.10 (0.0433) 803036073 1.25 (0.0492) 803036074 1.40 (0.0551) 803036075 0.65 (0.0256)
ST
MT-00492
2) Measure depth Y between the end of the ST and the transfer drive gear. ST 398643600 GAUGE
5) Install the selected thrust washer.
ST
ST
MT-00493
3) Using the following calculation, calculate the transfer drive gear thrust washer value t. t = {Y 15 mm (0.59 in)} {Z 15 mm (0.59 in)} 0.45 0.65 mm (0.018 0.026 in)
t mm (in) Y mm (in) Z mm (in) 0.45 0.65 mm (0.018 0.026 in) 15 mm (0.591 in) Transfer drive gear thrust washer thickness Depth between the end of the ST and the transfer drive gear Height from the end of the transmission case to the end of the ST. Standard clearance between the thrust washer and transfer drive gear Thickness of ST
6MT-49
Reverse Check System

12.Reverse Check System

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 4) Remove the snap ring and washer from the reverse check shaft.
(B)
6) Remove the spring pin, and remove the reverse check lever and oil seal from the reverse check shaft. NOTE: Do not reuse the oil seal.
(B) (C)
(A)
MT-00496
(A)
(A) Spring pin (B) Reverse check lever (C) Oil seal
MT-00494
7) Remove the plug from the extension case, and remove the gasket, spring and plunger. NOTE: Do not reuse the gasket.
(A) Snap ring (B) Washer
5) Remove the reverse check shaft and spring from the extension case.
(D) (C) (B) (A)
MT-01818
MT-00495
(A) (B) (C) (D)
Plug Gasket Spring Plunger
8) Remove the reverse lock plunger.
(A)
MT-00498
(A) Reverse lock plunger
6MT-50

B: INSTALLATION
1) Insert the reverse lock plunger. 2) Install the reverse check plug, spring, gasket, and plug in order. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)

(B)
(A)
(D) (C) (B) (A)
MT-00494
(A) Snap ring (B) Washer
MT-01818
(A) (B) (C) (D)
Plug Gasket Spring Reverse check plug
5) Attach ST1 to the reverse check shaft. Install the new oil seal, and push it in using ST2. ST1 18671AA000 OIL SEAL GUIDE ST2 18657AA010 INSTALLER
ST2
3) Install the spring and reverse check shaft to the extension case. NOTE: Confirm that the end of the spring matches the hole of the reverse check shaft and the cut out of the extension case.
ST1 (A)
MT-00500
(A) Oil seal
(B) (A)
6) Insert the reverse check lever, and turn the reverse check shaft until the plunger is pushed in first.
(A) (B)
(B) (A) (C) (D) MT-00501
(A) Plunger (B) Reverse check shaft
MT-00499
(A) (B) (C) (D)
Reverse check shaft Spring Hole Cut out
6MT-51

7) Match the hole of the reverse check lever and the reverse check shaft, and attach the spring pin.
(C)
C: INSPECTION
1) Check that there is no damage on any parts. 2) Check that the reverse check lever is operating smoothly. 3) Inspect that there is no oil leak at the oil seal section of the reverse check shaft. If there is oil leakage, replace the oil seal. 4) Check the operation of the reverse check. (1) When the reverse check lever is in the following position, the plunger is pressed, or the gear can shift into reverse.
(A)
(B)
MT-00502
(A) Reverse check shaft (B) Reverse check lever (C) Hole
8) Check that the reverse check is operating correctly. <Ref. to 6MT-52, INSPECTION, Reverse Check System.> 9) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 10) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
MT-00503
(2) When the reverse check lever is in the following position, the plunger is not pressed, or the gear cannot shift into reverse.
MT-00504
5) If it is not as specified, reassemble the reverse check system.
6MT-52
Transfer Drive Gear

13.Transfer Drive Gear

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 4) Remove the transfer drive gear.
C: DISASSEMBLY
MT-00506
2) Remove the bearing using the ST. ST 499877000 RACE 4-5 INSTALLER NOTE: Do not reuse the ball bearing.
MT-00505
ST
B: INSTALLATION
1) Attach the transfer drive gear. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00507
MT-00505
2) When the ball bearing, transfer drive gear or snap ring are replaced, select an appropriate thrust washer for the transfer drive gear. <Ref. to 6MT-45, ASSEMBLY, Extension Case.> 3) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 4) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
6MT-53
Transfer Drive Gear

D: ASSEMBLY
1) Using the ST, install the ball bearing. ST1 499247400 INSTALLER ST2 398497701 SEATS
ST2
E: INSPECTION
1) Bearing Replace the bearings in the following cases. Breakage or rusting of the bearing Wear and damage The bearing does not rotate smoothly or an abnormal noise is emitted. 2) Drive gear Replace the drive gear in the following cases. The drive gear tooth surface and shaft are excessively broken or damaged. 3) Measure the clearance between the snap ring and ball bearing inner race with a thickness gauge. Standard clearance between the snap ring and inner race: 0 0.15 mm (0 0.0059 in)
ST1
MT-00508
2) Install the snap ring.
MT-00506
3) Inspect the clearance between the snap ring and the ball bearing. <Ref. to 6MT-54, INSPECTION, Transfer Drive Gear.>
MT-00509
4) If the measurement is not within specification, select a suitable snap ring.

Part number 805045050 805045060 805045070 Thrust washer Thickness mm (in) 1.76 (0.069) 1.88 (0.074) 2.00 (0.079)
After replacing the snap ring, reinspect the clearance.
6MT-54

14.Transfer Driven Gear

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 4) Remove the transfer driven gear.
C: DISASSEMBLY
1) Using the ST, remove the roller bearing (extension case side). ST 498515700 REMOVER
ST
MT-00511
2) Using the ST, remove the roller bearing (transmission case side). ST1 899858600 REMOVER ST2 899864100 REMOVER
MT-00510 ST2 ST1
B: INSTALLATION
1) Install the transfer driven gear.
MT-00512
MT-00510
2) When the bearing or the transfer driven gear is replaced, select an appropriate thrust washer for the transfer driven gear. <Ref. to 6MT-46, ADJUSTMENT, Extension Case.> 3) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 4) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
6MT-55

D: ASSEMBLY
1) Using the ST, install the roller bearing (extension case side). ST1 398177700 INSTALLER ST2 899864100 REMOVER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST2
(A)
ST1
MT-00513
(A) Roller bearing
2) Using the ST, install the roller bearing (transmission case side). ST 499757002 INSTALLER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST
(A)
MT-00514
(A) Roller bearing
E: INSPECTION
1) Bearing Replace the bearings in the following cases. Breakage or rusting of the bearing Wear and damage After applying transmission gear oil, bearing does not rotate smoothly or an abnormal noise is emitted. 2) Driven gear Replace the driven gear in the following cases. The driven gear tooth surface and shaft are excessively broken or damaged.
6MT-56
Center Differential
A: REMOVAL
1) Remove the manual transmission case from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 4) Remove the thrust washer and center differential.
B: INSTALLATION
1) Install the needle bearing.
MT-00516
(A) (B)
2) Install the transfer driven gear. <Ref. to 6MT-55, INSTALLATION, Transfer Driven Gear.> 3) Install the thrust washer and center differential.
(A) (B) MT-00515
(A) Thrust washer (B) Center differential
5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the needle bearing.
MT-00515
(A) Thrust washer (B) Center differential
MT-00516
4) When replacing the center differential, select and install the appropriate transfer drive gear and thrust washer. <Ref. to 6MT-46, ADJUSTMENT, Extension Case.> 5) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 6) Install the manual transmission case assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
C: INSPECTION
Check that there is no damage on the center differential. Replace if damaged.
6MT-57
Transmission Case
16.Transmission Case
A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the oil guides G and H.
(A) (B)
9) Using an ST, remove the neutral set spring and support. ST1 18756AA000 CLAW ST2 399893600 PLIER
ST2
ST1 MT-01092
10) Lift the striking rod, and remove the spring pin.
(A)
(B)
MT-01307
MT-01728
(A) Striking rod (B) Spring pin
11) Remove the selector arm No. 2 and the shifter arm.
(A) (B)
8) Remove the snap ring and flat washer from the selector arm area.
(A) (B) MT-01616
MT-01618
6MT-58
Transmission Case
12) Remove the transfer bearing holder. NOTE: Using a general tool may cause damage. Remove the bolt using the ST. ST 18663AA000 SOCKET
16) Remove the pilot bolt.
MT-01619
13) Remove the thrust washer on the main shaft section. 14) Remove the driven gear assembly shim and spacer.
MT-00528 (A)
17) Remove the holder reverse bolt.
MT-00526
(A) Driven gear ASSY
15) Remove the snap ring. 18) Remove the transmission case.
MT-00529
NOTE: If the oil guide is caught between the shift fork, it may be difficult to remove the transmission case. Move the oil guide, then remove. Do not pull on the transmission case with excessive force.
MT-00527
MT-00530
19) Remove any remaining liquid gasket from the transmission case and adapter plate.
6MT-59
Transmission Case
B: INSTALLATION
1) Check that the shifter fork and the interlock block are both shifted into the neutral position. If they are not, shift into the neutral position.
4) By inspecting from the pilot bolt attachment hole, check that the interlock block and the reverse interlock block are aligned to the neutral position. If not aligned, remove the transmission case, and shift the shifter fork and interlock block to the neutral position.
(B)
(A) MT-00533 (A)
(A) Interlock block (B) Reverse interlock block
(B) (C)
5) Use a new gasket to temporarily attach the pilot bolt. 6) Affix the transmission case with the bolts and nuts.
MT-01620
(A) Striking rod (B) Reverse interlock block (C) Interlock block
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 7) Tighten the pilot bolt. Tightening torque: 34 Nm (3.5 kgf-m, 25.1 ft-lb) 8) Tighten the holder reverse bolt. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
2) Apply liquid gasket to the adapter plate. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
MT-00532
3) Install the transmission case.
6MT-60
Transmission Case
9) Install the snap ring, washer and collar of the driven gear assembly.
(C)
13) Install the selector arm No. 2 and the shifter arm.
(A) (B)
(B)
(A)
MT-01618

(A) (C)
14) Install a new spring pin. 15) Using the ST, install the neutral set spring. ST1 18756AA000 CLAW ST2 399893600 PLIER
(B)
(D) MT-01621 ST2
(A) (B) (C) (D)
Washer Snap ring Collar Washer
ST1 MT-01092
10) Attach the thrust washer to the main shaft. 11) Install the transfer bearing holder. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) ST 18663AA000 SOCKET
16) Install the snap ring and flat washer to the selector arm area.
(A) (B) MT-01616
MT-01619
12) When replacing the transfer bearing holder, select the appropriate transfer driven gear and thrust washer, and install to the extension case. <Ref. to 6MT-46, ADJUSTMENT, Extension Case.>
6MT-61
Transmission Case
17) Install the oil guides G and H.

(A) (B)
C: DISASSEMBLY
1) Remove the oil guides C, D, E and F.
(A)
MT-01728
18) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 19) Install the transfer driven gear. <Ref. to 6MT55, INSTALLATION, Transfer Driven Gear.> 20) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 21) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 22) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
(D)
T (C) (B) MT-01622
(A) (B) (C) (D)
Oil guide C Oil guide D Oil guide E Oil guide F
2) Remove the harness bracket.
MT-00538
3) Remove the oil pan.
MT-00539
4) Remove any remaining liquid gasket from the transmission case and oil pan.
6MT-62
Transmission Case
D: ASSEMBLY
1) Apply liquid gasket to the oil pan. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
4) Install the oil guides C, D, E and F. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A)
MT-00541
(D)
2) Install the oil pan. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
T (C) (B) MT-01622
(A) Oil guide C (B) Oil guide D (C) Oil guide E (D) Oil guide F
MT-00539
3) Install the ball, valve spring and a new O-ring. Tightening torque: T: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
E: INSPECTION
1) If the sludge is accumulated in the oil pan, use a waste cloth to wipe it off completely. 2) Check that there is no damage on any parts. Replace damaged parts with new parts.
(A) T
MT-01813
(A) Harness bracket
6MT-63
Main Shaft Assembly

17.Main Shaft Assembly

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the transmission case. <Ref. to 6MT58, REMOVAL, Transmission Case.> 8) Remove the striking rod. 9) Remove the oil guide B.
11) Remove the reverse idler holder.
(A)
MT-00544
(A) Reverse idler holder
12) Remove the check plug, O-ring, check spring, plunger and check ball from the adapter plate. NOTE: Do not reuse the O-ring.
MT-01623
(A) (B) (C) (D) (E) (C) (B) (A)
10) Use a screwdriver to shift to the 4th gear position.
MT-00545 (A)
MT-00543
(A) (B) (C) (D) (E)
Check plug O-ring Check spring Plunger Check ball
(A) 3rd-4th shift rod
6MT-64
Main Shaft Assembly

13) Remove the bolt and gasket holding the reverse idler shaft.
B: INSTALLATION
1) Adjust the 3rd-4th and 5th-6th shifter fork rods. <Ref. to 6MT-115, ADJUSTMENT, Shifter Fork and Rod.> 2) Turn the sub gear counterclockwise for approximately 3 teeth. Match the sub gear and reverse idler gear holes, and insert the ST. ST 18757AA000 STRAIGHT PIN
ST
MT-00546
(A)
14) Push the main shaft assembly, driven gear assembly, reverse idler gear and shifter forks to remove from the adapter plate all at once. NOTE: A helper is required to perform this work.
(B)
MT-00547
(A) Sub gear (B) Reverse idler gear
3) Attach the driven gear assembly to the 1st-2nd shifter fork assembly.
(C)
(B)
(A)
MT-00548
(A) 1st-2nd shifter fork (B) Driven gear ASSY (C) 1st-2nd sleeve
6MT-65
Main Shaft Assembly

4) Attach the main shaft assembly to the 3rd-4th shifter fork, and assemble to the driven gear assembly.
(A) (D) (B)
6) Attach the reverse shifter fork assembly to the reverse idler gear assembly.
(B)
(A)
(C) (C) (A) (D) (B)
MT-00551
(A) Reverse idler gear ASSY (B) Reverse shifter fork (C) Reverse sleeve
7) Install the reverse idler gear assembly.

(A)
(C) MT-00549
(A) (B) (C) (D)
3rd-4th shifter fork 3rd-4th sleeve Driven gear ASSY Main shaft ASSY
(B)
(C) MT-00552
(A) Reverse idler gear ASSY (B) 1st drive gear (C) Reverse gear
5) Attach the 5th-6th shifter fork assembly to the main shaft assembly.
(C) (B)
8) Install the thrust bearing of the driven gear assembly. 9) Push on the shifter forks, main shaft assembly, driven gear assembly and reverse idler gear assemblies, to attach to the adapter plate all at once. NOTE: A helper is required to perform this work.
MT-00550
(A)
(A) 5th-6th shifter fork (B) 5th-6th sleeve (C) Main shaft ASSY
6MT-66
Main Shaft Assembly

10) Install the plunger, check spring, new O-ring and check plugs. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
11) Install the check ball, check spring, new O-ring and check plugs. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A) (B) (C) (D) (D) (C) (B) (A)
MT-00553
MT-00554
(A) (B) (C) (D)
Check plug O-ring Check spring Plunger
(A) (B) (C) (D)
Check plug O-ring Check spring Check ball
12) Install a bolt and a new gasket. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00546
13) Use a screwdriver to shift to the 4th gear position.
6MT-67
Main Shaft Assembly

14) Install the reverse idler holder.
C: DISASSEMBLY
NOTE: Individual sleeves and hubs meet at a specified position. Before disassembly, mark the meeting position of the sleeve and hub. 1) Affix the ST to the work table. ST 18664AA000 BASE 2) Flatten the tab of the lock nut. 3) Set the main shaft assembly to the ST, and remove the lock nut and washer. ST1 18665AA000 HOLDER ST2 18664AA000 BASE NOTE: Use a 38 mm socket wrench.
(A)
MT-00544
(A) Reverse idler holder
15) Install the oil guide B. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
ST2
ST1
MT-00556
4) Remove the main shaft assembly from the ST.

MT-01623
16) Install the striking rod. 17) Install the transmission case. <Ref. to 6MT-60, INSTALLATION, Transmission Case.> 18) Install the selected main shaft snap ring and washers. 19) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 20) Install the transfer driven gear. <Ref. to 6MT55, INSTALLATION, Transfer Driven Gear.> 21) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 22) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 23) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
6MT-68
Main Shaft Assembly

5) Set the ST1 to the 6th drive gear, and use a press to remove the taper roller bearing, bushing and 6th drive gear. ST1 18722AA010 REMOVER ST2 899864100 REMOVER
ST2 ST1
7) Set the ST to the 3rd drive gear, and use a press to remove individual parts. ST 18720AA000 REMOVER
(B)
(A)
ST
ST (A)
ST1 (B) (C) (B)
MT-01406 MT-00557
(A) 3rd drive gear (B) 3rd-4th sleeve
(A) Taper roller bearing (B) Bushing (C) 6th drive gear
6) Remove the 5th-6th sleeve, 6th needle bearing and 6th baulk ring.
(A)
(B)
(C) MT-00558
(A) Needle bearing (B) 6th baulk ring (C) 5th-6th sleeve
6MT-69
Main Shaft Assembly

D: ASSEMBLY
NOTE: When replacing the following parts, replace as a set. Sleeve and hub Outer baulk ring, 3rd synchro cone and inner baulk ring Taper roller bearing 1) Apply adequate transmission gear oil to the main shaft, 3rd needle bearing and 3rd drive gear inner surface. 2) Install the 3rd needle bearing and 3rd drive gear to the main shaft.
3) Install the inner baulk ring, 3rd synchro cone and outer baulk ring.
(A) (B)
MT-00561
(A) Inner baulk ring (B) Outer baulk ring
(A)
NOTE: Install the 3rd synchro cone by aligning the protrusion of the 3rd synchro cone with the hole on the 3rd drive gear.
(B)
MT-00560
(A) 3rd needle bearing (B) 3rd drive gear
MT-01501
6MT-70
Main Shaft Assembly

4) Install the 3rd-4th hub and 4th bushing. (1) Being careful of the install direction of the 3rd-4th hub, set to the main shaft.
(A) (B)
(3) Using the ST, push in to the 3rd-4th hub and 4th bushing all at once. ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton). NOTE: When pushing into the 3rd-4th hub and 4th bushing, move the outer baulk ring to match the protrusion of the outer baulk ring and the cut out on the 3rd-4th bushing.
(C) MT-00884
(A) Main shaft (B) 3rd-4th hub (C) 3rd drive gear
(E)
ST1 (A)
(2) Being careful not to cover the oil holes of the main shaft and 4th bushing, attach to the main shaft.
(A) A (E) (A) A
ST2
(B)
(C)
(C)
(D) (D) (B)
MT-00555 (C)
(A) 3rd-4th hub (B) (C) (D) (E) Outer baulk ring Cut out on the 3rd-4th hub Protrusion of the outer baulk ring 4th bushing
(A)
(D) A-A MT-01819
(A) 4th bushing (B) 3rd-4th hub (C) 4th bushing oil hole (D) Main shaft oil hole
5) Make sure that the 3rd drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
6MT-71
Main Shaft Assembly

6) Attach the 3rd-4th shifting insert key at the appropriate position of the 3rd-4th sleeve. NOTE: The angle of each shifting insert key is 120. Refer to the following figure to install the shifting insert key.
)A( (A)
8) Install the 4th baulk ring.
MT-00564
(B)
9) Apply adequate transmission gear oil to the main shaft, 4th needle bearing and 4th drive gear inner surface. 10) Install the 4th needle bearing and 4th drive gear.
(B) (C) (A) (B)
MT-00565 MT-01820
(A) Attach the straight part of the shifting insert key to the sleeve convex portion. (B) 3rd-4th shifting insert key (C) 3rd-4th sleeve
(A) 4th needle bearing (B) 4th drive gear
7) Attach the 3rd-4th sleeve to the 3rd-4th hub. NOTE: There is an identification groove on the 3rd-4th sleeve. Place the groove towards the 3rd drive gear, and attach the 3rd-4th sleeve.
(B) (A) MT-00563
(A) 3rd drive gear (B) 3rd-4th sleeve identification groove (1)
6MT-72
Main Shaft Assembly

11) Install the 5th bushing. (1) Being careful not to cover the oil holes of the main shaft and 5th bushing, attach to the main shaft.
(A) A
14) Install the 5th needle bearing and 5th drive gear.
(B) (A)
(D)
(C) A MT-00568
(B) (E)
(A) 5th needle bearing (B) 5th drive gear

(D) (A)
(B) A-A MT-01821
(A) 5th bushing (B) (C) (D) (E) Main shaft oil hole Main shaft 5th bushing oil hole 4th drive gear
MT-00569
(2) Using the ST, push into the 5th bushing. ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
ST1
ST2 MT-00567
12) Make sure that the 4th drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble. 13) Apply adequate transmission gear oil to the main shaft, 5th needle bearing and 5th drive gear inner surface.
6MT-73
Main Shaft Assembly

16) Install the 5th-6th hub. (1) Being careful of the install direction of the 5th-6th hub, set to the main shaft.
(A)
17) Make sure that the 5th drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble. 18) Attach the 5th-6th shifting insert key at the appropriate position of the 5th-6th sleeve. NOTE: The angle of each shifting insert key is 120. Refer to the following figure to install the shifting insert key.
)A( (A)
(B)
(C) MT-00570
(A) Main shaft (B) 5th-6th hub (C) 5th drive gear
(B)
(2) Using the ST, push into the 5th-6th hub. ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton). NOTE: When pushing into the 5th-6th hub, move the outer baulk ring to match the protrusion of the outer baulk ring and the cut out on the 5th-6th bushing.
ST1 (A) (B) (C)
MT-01820
(A) Attach the straight part of the shifting insert key to the sleeve convex portion. (B) 5th-6th shifting insert key (C) 5th-6th sleeve
19) Attach the 5th-6th sleeve to the 5th-6th hub.

ST2
(C)
(A)
NOTE: There are two identification grooves on the 5th6th sleeve. Place the grooves towards the 5th drive gear, and attach the 5th-6th sleeve.
(D)
(B) (B)
MT-00571 (A)
(A) (B) (C) (D)
5th-6th hub Outer baulk ring Cut out on the 5th-6th hub Protrusion of the outer baulk ring
MT-00572
(A) 5th drive gear (B) 5th-6th sleeve identification groove (2)
6MT-74
Main Shaft Assembly

25) Using the ST, install the 6th bushing. ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
ST1
MT-00573
21) Apply adequate transmission gear oil to the main shaft, 6th needle bearing and 6th drive gear inner surface. 22) Install the 6th drive gear.
ST2 MT-00577
26) Make sure that the 6th drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble. 27) Using the ST, install the inner bearing of the taper roller bearing. ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER
MT-00574
23) Install the 6th needle bearing.
CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
ST1
ST2 MT-00575 MT-00578
24) Being careful not to cover the oil holes of the 6th bushing and the main shaft, set the 6th bushing to the main shaft.
(A)
(B) MT-01822
(A) 6th bushing oil hole (B) Main shaft oil hole
6MT-75
Main Shaft Assembly

28) Using the ST, install the outer race and the outer bearing of the taper roller bearing. ST1 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton). NOTE: Confirm that the outer race is installed in the proper direction. Push in until there is no backlash on the outer race and the bearing turns smoothly by hand.
ST1 (B) (A)
31) Set the main shaft assembly to the ST, and tighten the lock nut. ST1 18665AA000 HOLDER ST2 18664AA000 BASE Tightening torque: 392 Nm (40.0 kgf-m, 289.1 ft-lb)
ST2
ST1
MT-00556
32) Using the ST, crimp the lock nut in 4 locations, with dimensions within A 27r0.3 mm (1.06r0.01 in). ST 18668AA000 PUNCH NOTE: Do not damage the crimp area of the lock nut.
ST2
ST
(A)
MT-00579
(A) Outer race (B) Outer bearing of the taper roller bearing
29) Make sure that the taper roller bearing turns smoothly by hand. If it does not rotate smoothly, replace the taper roller bearing as a set, and reassemble. 30) Attach the lock washer and a new lock nut.
A
MT-00580
6MT-76
Main Shaft Assembly

E: INSPECTION
Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully. 1) Bearing Replace the bearings in the following cases. Wear, rusting or damage of the bearings The bearing does not rotate smoothly or an abnormal noise is emitted when turning. The bearing has other defects. 2) Bushing (each gear) Replace the bushing in following cases. The sliding surface is damaged or abnormally worn. 3) Gear Replace gears in the following cases. The gear teeth surface is damaged or excessively worn. The contact area of the baulk ring is damaged. The inner face of the gear is worn. 4) Baulk ring, synchro cone Replace the baulk ring and synchro cone in the following cases. Wear, rusting or damage of the baulk ring 5) Shifting insert key Replace the shifting insert key if deformed, excessively worn or defective in any way.
F: ADJUSTMENT
1. MAIN SHAFT SNAP RING & WASHER SELECTION
NOTE: In the following conditions, perform the procedures below. Replacing driven gears 1st through 6th Replacing the 1st and 2nd synchro ring assembly Replacing the ball bearing Replacing the adapter plate Replacing the driven shaft 1) Insert the drive pinion assembly into the adapter plate. NOTE: Confirm that the thrust bearing outer race has not been removed and the drive pinion is not lifted. 2) Set the height gauge to the adapter plate. Lower the height gauge indicator to the mating surface of the adapter plate and case, and set to zero points. ST 18853AA000 HEIGHT GAUGE
ST
MT-00582
MT-00581
NOTE: The adapter plate will be the base point for the measurement. Use a scraper to remove any gasket material remaining on the end face. During measurement, do not place the height gauge in the shaded area shown in the figure.
MT-00583
6MT-77
Main Shaft Assembly

3) Measure the height to the ball bearing end face (height H).
4) According to the measurement value, select the snap ring and washer from the following table. Snap ring
H: mm (in) 270.83 271.40 (10.66 10.69) 271.41 271.98 (10.69 10.71) 271.99 272.56 (10.71 10.73) Part No. 805072010 805072011 805072012 Thickness: mm (in) 1.65 (0.065) 1.95 (0.077) 2.25 (0.089)
(A)
Washer
H: mm (in) 270.83 271.40 (10.66 10.69) 271.41 271.98 (10.69 10.71) 271.99 272.56 (10.71 10.73) Part No. 803067012 803067011 803067010 Thickness: mm (in) 1.6 (0.063) 1.3 (0.051) 1.0 (0.039)
MT-00955
(A) Ball bearing
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the end face of the bearing.
(2)
(1)
MT-00585
Turn approximately 120 at a time, and measure the ball bearing in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
6MT-78
Driven Gear Assembly

18.Driven Gear Assembly

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the transmission case. <Ref. to 6MT58, REMOVAL, Transmission Case.> 8) Remove the driven gear assembly. <Ref. to 6MT-64, REMOVAL, Main Shaft Assembly.> 9) Remove the 1st needle bearing.
B: INSTALLATION
1) Adjust the main shaft snap ring. <Ref. to 6MT77, ADJUSTMENT, Main Shaft Assembly.> 2) Adjust the 1st-2nd shifter rod. <Ref. to 6MT-115, ADJUSTMENT, Shifter Fork and Rod.> 3) Install the thrust needle bearing. NOTE: Confirm that the thrust needle bearing is installed in the proper direction.
MT-00587
MT-00586
10) Remove the thrust needle bearing.
4) Install the 1st needle bearing. 5) Install the driven gear assembly. <Ref. to 6MT65, INSTALLATION, Main Shaft Assembly.> 6) Install the transmission case. <Ref. to 6MT-60, INSTALLATION, Transmission Case.> 7) Adjust the backlash of the driven gear assembly in the axial direction. <Ref. to 6MT-87, ADJUSTMENT, Driven Gear Assembly.> 8) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 9) Install the transfer driven gear. <Ref. to 6MT-55, INSTALLATION, Transfer Driven Gear.> 10) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 11) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 12) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
6MT-79

C: DISASSEMBLY
NOTE: Individual sleeves and hubs meet at a specified position. Before disassembly, mark the meeting position of the sleeve and hub. 1) Affix the ST to the work table. ST 18664AA000 BASE 2) Flatten the tab of the axle nut. 3) Attach ST3 to the lock nut, set the driven gear assembly to the ST, and remove the lock nut and washer. ST1 18666AA000 HOLDER ST2 18664AA000 BASE ST3 18620AA000 ADAPTER WRENCH
5) Attach ST1 to the 4th gear, then remove the 3rd4th driven gear. ST1 18723AA000 REMOVER ST2 499877000 RACE 4-5 INSTALLER
ST2
(A)
ST1
MT-01481
(A) 3rd-4th driven gear
6) Remove the driven gear key.

ST3 ST2
ST1 MT-00588
4) Attach ST1 to the 6th gear, then remove the ball bearing and 5th-6th driven gear. ST1 18723AA000 REMOVER ST2 499877000 RACE 4-5 INSTALLER
ST2 ST1 (A)
MT-00590
7) Remove the 2nd gear.
(B)
MT-01480
MT-00591
(A) Ball bearing (B) 5th-6th driven gear
8) Remove the needle bearing and 1st-2nd sleeve.
(A) (B)
MT-00592
(A) Needle bearing (B) 1st-2nd sleeve
6MT-80

9) Remove the outer baulk ring, 2nd synchro cone and inner baulk ring.
D: ASSEMBLY
NOTE: When replacing the following parts, replace as a set. Sleeve and hub Outer baulk ring, 1st synchro cone and inner baulk ring Outer baulk ring, 2nd synchro cone and inner baulk ring 1) Apply adequate transmission gear oil to the main shaft, 1st needle bearing and 1st drive gear inner surface. 2) Install the 1st needle bearing.
(C) (B) (A)
MT-01502
(A) Outer baulk ring (B) 2nd synchro cone (C) Inner baulk ring
10) Using the ST, remove individual parts. ST 18754AA000 REMOVER
MT-00595 ST
3) Attach the 1st driven gear to the driven shaft.
(A) (B) (E) ST (C) (D) (F) (G) MT-00594
MT-01503
4) Install the inner baulk ring.
(A) (B) (C) (D) (E) (F) (G)
2nd bushing 1st-2nd hub Outer baulk ring 1st synchro cone Inner baulk ring 1st driven gear 1st needle bearing
MT-01504
6MT-81

5) Match the protrusion of the 1st synchro cone to the hole of the 1st drive gear, then install.
7) Install the 1st-2nd hub. NOTE: Match the cut out of the 1st-2nd hub with the protrusion on the outer baulk ring, then install. Make sure that the 1st-2nd hub is installed in the correct direction.
(C) (A) (D) (B) (E)
MT-01505
6) Install the outer baulk ring.
(A) MT-00599 (E)
MT-00600
(A) (B) (C) (D) (E)
1st-2nd hub Outer baulk ring 1st-2nd hub cut out section Protrusion of the outer baulk ring 1st driven gear
8) Using the ST, install the 2nd hub. ST 18654AA000 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
ST
(A) (B)
MT-00601
(A) 2nd bushing (B) 1st-2nd hub
6MT-82

9) Make sure that the 1st drive gear can be turned smoothly by hand. If it does not turn smoothly, reassemble. 10) Attach the shifting insert key to the appropriate position of the 1st-2nd sleeve. NOTE: The angle of each shifting insert key is 120. Refer to the following figure to install the shifting insert key.
)A( (A)
11) Attach the 1st-2nd sleeve to the 1st-2nd hub. NOTE: Make sure that the 1st-2nd sleeve is installed in the correct direction.
(B)
(A)
(B)
(B) (C) (B) (C) MT-00603
(A) 1st driven gear (B) 1st-2nd sleeve (C) 1st driven gear side
MT-01823
12) Install the outer baulk ring.

(A) Attach the straight part of the shifting insert key to the sleeve convex portion. (B) 1st-2nd shifting insert key (C) 1st-2nd sleeve
MT-00604
13) Install the 2nd synchro cone.
MT-01506
6MT-83

14) Install the inner baulk ring.
18) Using the ST, install the 3rd-4th driven gear. ST 18654AA000 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton). NOTE: Make sure that the 3rd-4th driven gear is installed in the correct direction. Match the groove on the 3rd-4th driven gear to the key.
MT-00606
15) Apply adequate transmission gear oil to the bushing, 2nd needle bearing and 2nd drive gear inner surface. 16) Install the 2nd needle bearing and 2nd driven gear. NOTE: Match the protrusion of the 2nd synchro cone to the hole of the 2nd driven gear, then install.
ST
(A)
(B) (C)
MT-00609
(A) (B)
(A) 4th gear (B) 3rd gear (C) 2nd gear
(C) MT-00607
19) Make sure that the 2nd driven gear can be turned smoothly by hand. If it does not turn smoothly, reassemble. 20) Attach the key.
(A) 2nd needle bearing (B) 2nd driven gear (C) Protrusion of the 2nd synchro cone
17) Attach the key.
MT-00610
MT-00608
6MT-84

21) Using the ST, install the 5th-6th driven gear. ST 18654AA000 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton). NOTE: Make sure that the 5th-6th driven gear is installed in the correct direction. Match the groove on the 5th-6th driven gear to the key.
ST (A) (B) (C)
25) Attach ST3 to the lock nut, attach ST to the driven gear assembly, and tighten the lock nut. ST1 18666AA000 HOLDER ST2 18664AA000 BASE ST3 18620AA000 ADAPTER WRENCH ST4 18852AA000 TORQUE WRENCH Tightening torque: 530 Nm (54.0 kgf-m, 390.9 ft-lb)
ST4 ST3 ST2
ST1 MT-00613
MT-00611
(A) 6th gear (B) 5th gear (C) 4th gear
NOTE: When using a torque wrench other than ST4, use the calculation below to calculate and tighten the lock nut. T = L1 / (0.1 + L1) 570
Nm(kgf-m, ft-lb) m (in) 0.1 m (3.94 in) 570 Nm (58.1 kgf-m, 420 ft-lb) T L1 Torque wrench setting Torque wrench length Length of ST Tightening torque (lock nut)
22) Using the ST, install the ball bearing. ST 18654AA000 INSTALLER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton). NOTE: Confirm that the ball bearing is installed in the proper direction.
ST
(A)
L1
MT-00614
(A) 0.1 m (3.94 in)

MT-00612
23) Make sure that the ball bearing turns smoothly by hand. If it does not turn smoothly, reassemble. 24) Install a new lock nut.
6MT-85

26) Using the ST, crimp the lock nut in 4 locations, with dimensions within A 44r0.5 mm (1.73r0.02 in). ST 18669AA000 PUNCH DRIVEN SHAFT NOTE: Do not damage the crimp area of the lock nut.
ST
E: INSPECTION
Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully. 1) Bearing Replace the bearings in the following cases. Wear, rusting or damage of the bearings The bearing does not rotate smoothly or an abnormal noise is emitted when turning. The bearing has other defects. 2) Bushing (each gear) Replace the bushing in following cases. The sliding surface is damaged or abnormally worn. 3) Gear Replace gears in the following cases. The gear teeth surface is damaged or excessively worn. The contact area of the baulk ring is damaged. The inner face of the gear is worn. 4) Baulk ring, synchro cone Replace the baulk ring and synchro cone in the following cases. Wear, rusting or damage of the baulk ring 5) Shifting insert key Replace the shifting insert key if deformed, excessively worn or defective in any way.
MT-00615
MT-00581
6MT-86

F: ADJUSTMENT
1) Measure the length H from the transmission case and transfer bearing holder mating surface, to the end face of the ball bearing.
(C) H (B) MT-00616 (A)
(A) Transmission case (B) Ball bearing (C) Driven gear ASSY
2) Using the following calculation, calculate the thickness of the driven gear assembly washer. T = H {5.8r0.05 mm (0.23r0.002 in)} {0.1 0.3 mm (0.0039 0.0118 in)}
t H Washer thickness Length from the transmission case and transfer bearing holder mating surface to the end face of the ball bearing Collar thickness
5.8r0.05 mm (0.23r0.002 in) 0.1 0.3 mm Driven gear assembly axial direc(0.0039 0.0118 in) tion backlash standard
3) Select 0 to 3 washers from the following table, and adjust to the backlash that is closest to the standard value. Driven gear assembly axial direction backlash standard: 0.1 0.3 mm (0.0039 0.0118 in)
Washer Part No. 803072030 803072031 803072032 803072033 Thickness t mm (in) 0.15 (0.0059) 0.30 (0.0118) 0.45 (0.0177) 0.60 (0.0236)
6MT-87
Reverse Idler Gear Assembly

19.Reverse Idler Gear Assembly

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the transmission case. <Ref. to 6MT58, REMOVAL, Transmission Case.> 8) Remove the reverse idler gear assembly. <Ref. to 6MT-64, REMOVAL, Main Shaft Assembly.>
C: DISASSEMBLY
NOTE: Sleeves and reverse gears meet at a specified position. Before disassembly, mark the meeting position of the sleeve and hub. 1) Remove the spring pin.
MT-00617
2) Remove the snap ring and washer.
B: INSTALLATION
1) Select the reverse fork rod. <Ref. to 6MT-115, ADJUSTMENT, Shifter Fork and Rod.> 2) Install the reverse idler gear assembly. <Ref. to 6MT-65, INSTALLATION, Main Shaft Assembly.> 3) Install the transmission case. <Ref. to 6MT-60, INSTALLATION, Transmission Case.> 4) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 5) Install the transfer driven gear. <Ref. to 6MT-55, INSTALLATION, Transfer Driven Gear.> 6) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 7) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 8) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
MT-00618
3) Remove the counter high & low washer and reverse idler gear.
(A)
(B)
MT-00619
(A) Counter high and low washer (B) Reverse idler gear
6MT-88

4) Remove the knock pin and reverse idler gear needle bearing.
(B)
8) Remove reverse idler gear No. 2.
(A)
MT-00624 MT-00620
(A) Knock pin (B) Reverse idler gear needle bearing
9) Remove the counter high & low washer and needle bearing.
5) Remove the collar. 6) Remove the reverse sleeve.

(A)
(B)
MT-00625
(A) Needle bearing (B) Counter high and low washer

MT-00622
10) Remove the knock pin.
7) Remove the outer baulk ring, reverse synchro cone and inner baulk ring from the reverse sleeve.
(B) (C) (D)
MT-00626 (A) MT-01507
11) Remove the snap ring and friction plate from reverse gear.
(A) (B) (C) (D)
Reverse sleeve Outer baulk ring Reverse synchro cone Inner baulk ring
(A)
(B)
MT-00627
(A) Snap ring (B) Friction plate
6MT-89

12) Remove the sub gear and spring.

(A) (B)
D: ASSEMBLY
1) Attach the sub gear and spring. NOTE: Turn the white marking on the hook section towards the sub gear side, and attach the spring. Point the stamp (marking A) towards the outside, and install the sub gear.
(A) MT-00628 (B)
(C)
(A) Sub gear (B) Spring (C) Stamp (Marking A)

A
A (C)
MT-00628
(A) Sub gear (B) Spring (C) Stamp (Marking A)
While paying attention to the direction of the sub gear attachment hole, attach the spring and sub gear.
(A) MT-00629
(A) Attachment hole
6MT-90

2) Install the friction plate and snap ring. NOTE: Confirm that the friction plate is installed in the proper direction.
(C)
6) Install the reverse idler gear No. 2.
(D) (B) MT-00632 (A) MT-00630
7) Attach the shifting insert key to the appropriate location of the reverse sleeve. NOTE: The angle of each shifting insert key is 120.
(A) (B)
(A) (B) (C) (D)
Friction plate Snap ring Snap ring side Sub gear side
3) Apply adequate transmission gear oil to the shaft, needle bearing and reverse drive gear inner surface. 4) Install the knock pin.
(A)
(B)
MT-00626
5) Install the counter high and low washer and the needle bearing. NOTE: Point the groove towards the reverse idler gear, and attach the washer.
(A) Reverse sleeve (B) Shifting insert key
MT-00633
(C)
(B) (A) MT-00631
(A) Groove (B) Counter high and low washer (C) Needle bearing
6MT-91

8) Attach the reverse sleeve to the reverse idler gear No. 2. NOTE: Confirm that the reverse sleeve is installed in the proper direction.
12) Match the protrusion of the reverse synchro cone to the hole on the reverse idler gear, and install the reverse idler gear.
(A) (B)
MT-01508
MT-00634
(A) Protrusion on the reverse synchro cone (B) Hole of the reverse idler gear
9) Apply adequate transmission gear oil to the collar, needle bearing and reverse drive gear inner surface. 10) Install the outer baulk ring, reverse synchro cone and inner baulk ring.
13) Point the groove towards the reverse idler gear, and attach the counter high and low washer, and the washer. 14) Using the ST, install the snap ring. ST 18672AA000 GUIDE CLIP
ST
(A)
(B)
(C)
MT-00635 MT-00638
(A) Outer baulk ring (B) Reverse synchro cone (C) Inner baulk ring
11) Install the collar and needle bearing, then the knock pin.
15) Inspect and adjust the clearance between the snap ring and the washer. <Ref. to 6MT-93, INSPECTION, Reverse Idler Gear Assembly.> 16) Install a new spring pin.
(C) (B)
(A)
MT-00636
(A) Collar (B) Needle bearing (C) Knock pin
6MT-92

E: INSPECTION
Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully. 1) Bearing Replace the bearings in the following cases. Wear, rusting or damage of the bearings The bearing does not rotate smoothly or abnormal noise is emitted when turning. The bearing has other defects. 2) Bushing (each gear) Replace the bushing in following cases. The sliding surface is damaged or abnormally worn. 3) Gear Replace gears in the following cases. The gear teeth surface is damaged or excessively worn. The contact area of the baulk ring is damaged. The inner face of the gear is worn. 4) Baulk ring, synchro cone Replace the baulk ring and synchro cone in the following cases. Wear, rusting or damage of the baulk ring 5) Shifting insert key Replace the shifting insert key if deformed, excessively worn or defective in any way.
6) Check clearance between the snap ring and washer. Clearance specification: 0.1 0.3 mm (0.0039 0.0118 in)
MT-00639
If the clearance is out of the specification, select a snap ring from the following table and replace it.
Snap ring Part No. 031319000 805019030 805019010 Thickness mm (in) 1.50 (0.059) 1.60 (0.062) 1.72 (0.068)
After replacing the snap ring, inspect the clearance.
MT-00581
6MT-93


A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the transmission case. <Ref. to 6MT58, REMOVAL, Transmission Case.> 8) Remove the individual gear assemblies. <Ref. to 6MT-64, REMOVAL, Main Shaft Assembly.> 9) Remove the drive pinion shaft assembly.
B: INSTALLATION
1) Remove any remaining gasket material from the drive plate and clutch housing. 2) Apply liquid gasket to the clutch housing. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
MT-00532
MT-00640
3) Install the individual gear assemblies. <Ref. to 6MT-65, INSTALLATION, Main Shaft Assembly.> 4) Install the transmission case. <Ref. to 6MT-60, INSTALLATION, Transmission Case.> 5) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 6) Install the transfer driven gear. <Ref. to 6MT-55, INSTALLATION, Transfer Driven Gear.> 7) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 8) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 9) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
6MT-94

C: DISASSEMBLY
NOTE: Replace the drive pinion shaft and hypoid driven gear as a set. 1) Remove the oil guide A.
(A)
6) Using the ST, remove the taper roller bearing assembly. ST 18723AA000 REMOVER
ST
MT-00644
MT-01624
(A) Oil guide A
2) Remove the drive pinion shaft and shim from the adapter plate.
MT-00642
3) Affix the ST to the work table. ST 18664AA000 BASE 4) Flatten the tab of the axle nut. 5) Attach ST3 to the lock nut, and set the drive pinion shaft to ST. Remove the lock nut and washer. ST1 18667AA000 HOLDER ST2 18664AA000 BASE ST3 18621AA000 ADAPTER WRENCH
ST3
ST2
ST1
MT-00643
6MT-95

D: ASSEMBLY
1) Using the ST, measure drive pinion measurement A. NOTE: When selecting the drive pinion shim, refer to measurement A. ST 398643600 GAUGE
4) Attach the washer and a new lock nut. 5) Set the ST to the drive pinion, and tighten the lock nut. ST1 18667AA000 HOLDER ST2 18664AA000 BASE ST3 18621AA000 ADAPTER WRENCH ST4 18852AA000 TORQUE WRENCH NOTE: Tighten using the ST and the straight line torque wrench. Tightening torque: 265 Nm (27.0 kgf-m, 195.4 ft-lb)
ST3 ST4
ST A MT-00645 ST1 ST2
2) Using the ST and a press, attach the inner bearing of the taper roller bearing to the drive pinion shaft. ST 18723AA000 REMOVER CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
MT-00648
ST
NOTE: When using a torque wrench other than ST4, use the calculation below to calculate and tighten the lock nut. Tighten using the ST and the straight line torque wrench. T = L1 / (0.1 + L1) 285
Nm(kgf-m, ft-lb) m (in) 0.1 m (3.94 in) 285 Nm (29.0 kgf-m, 210 ft-lb) T L1 Torque wrench setting Torque wrench length Length of ST Tightening torque (lock nut)
MT-00646
3) Using the ST and a press, attach the outer race and the taper roller bearing to the drive pinion shaft. ST 18723AA000 REMOVER NOTE: Push in to a position where the bearing rotates smoothly.
(A) ST MT-00614 (A) L1
(A) 0.1 m (3.94 in)
6) Measure the starting torque. <Ref. to 6MT-98, INSPECTION, Drive Pinion Shaft Assembly.>
MT-00647
(A) Outer race
6MT-96

7) Using the ST, crimp the lock nut in 2 locations, with dimensions within A 37r0.5 mm (1.46r0.02 in). ST 18670AA000 PUNCH NOTE: Do not damage the crimp area of the lock nut.
9) Calculate from the calculation below to select 1 or 2 drive pinion shims from the following table. 6.5r0.0625 mm (B A) [0.26r0.0025 in (B A)] NOTE: A: Measurement value in step 1) B: Measurement value in step 8)
Drive pinion shim Part No. Thickness mm (in) 32295AA270 0.15 (0.0059) 32295AA280 0.175 (0.0069) 32295AA290 0.20 (0.0079) 32295AA300 0.225 (0.0089) 32295AA310 0.25 (0.0098) 32295AA320 0.275 (0.0108)
ST
10) Apply transmission gear oil to the side face of the taper roller bearing, and attach the drive pinion shaft and the selected shims to the adapter plate. Tightening torque: 54 Nm (5.5 kgf-m, 40 ft-lb)
A
MT-00649
8) Using the ST, measure drive pinion measurement B. ST 398643600 GAUGE

MT-00642 ST
11) Install the oil guide A. Tightening torque: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A)
B MT-00650
MT-01624
(A) Oil guide A
6MT-97

E: INSPECTION
1) Using a spring scale, measure the starting torque. If the starting torque is outside the specification range, replace the taper roller bearing. Starting torque: 0 0.95 N (0 0.097 kgf, 0 0.21 lb)
3) Install the drive pinion shaft assembly to the clutch housing, and tighten at least 4 bolts. NOTE: Install with the remaining liquid gasket, so that the clutch housing and the adapter plate will not be damaged. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 4) Turn a few times using the ST. ST 18631AA000 HANDLE
ST
MT-00651
2) Gear Replace gears in the following cases. The gear teeth surface is damaged or excessively worn. 3) Bearing Replace the bearings in the following cases. Wear, rusting or damage of the bearings The bearing does not rotate smoothly or an abnormal noise is emitted when turning. 4) Adapter plate Replace the adapter plate in the following cases: Wear, rusting or damage of the bearings Damage of the adapter plate 5) Check that the pipes and pipe chambers are not damaged or clogged. Repair or replace if damaged or clogged.
MT-00653
5) Remove the drive pinion shaft assembly, and inspect the mating condition of the teeth. If the mating is not correct, change shim thickness to adjust backlash. Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)
(A)
F: ADJUSTMENT
1) Inspect and adjust the hypoid driven gear-todrive pinion backlash. <Ref. to 6MT-108, HYPOID GEAR BACKLASH, ADJUSTMENT, Front Differential Assembly.> 2) Apply a thin uniform coat of lead-free red dye on the surfaces of 3 or 4 hypoid driven gear teeth.
(B)
MT-01401
MT-00652
6MT-98

Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern
AT-00208
AT-00210
Corrective action: Reconfirm and adjust backlash.
Corrective action: Reduce the thickness of the drive pinion shim according to the procedure for moving the drive pinion away from the driven gear.
AT-01253
AT-00213
Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern
AT-00209
Corrective action: Reconfirm and adjust backlash.

AT-00211
Corrective action: Increase thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to the driven gear.
AT-01254
AT-00212
6MT-99


A: REMOVAL
1) Remove the manual transmission assembly. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the transmission case. <Ref. to 6MT58, REMOVAL, Transmission Case.> 8) Remove the individual gear assemblies. <Ref. to 6MT-64, REMOVAL, Main Shaft Assembly.> 9) Remove the drive pinion shaft assembly. <Ref. to 6MT-94, REMOVAL, Drive Pinion Shaft Assembly.> 10) Remove the lock plates on both sides.
11) Remove the differential side retainers on both sides using the ST. ST1 18630AA010 WRENCH COMPL RETAINER (RH SIDE) ST2 18630AA000 WRENCH ASSEMBLY (LH SIDE) NOTE: Be careful not to damage the section where the clutch case retainer will be attached.
(B) ST1
(A)
ST2
MT-00657
(A) LH side (B) RH side

(A) MT-01022
12) Remove the front differential.
(A) Lock plate
6MT-100

B: INSTALLATION
1) Install the differential assembly to the clutch housing. 2) Apply oil to the screw threads of the side retainer. 3) Remove the O-rings on both sides of the side retainer. 4) Install the differential side retainers to both sides, using the ST. ST1 18630AA010 WRENCH COMPL RETAINER (RH SIDE) ST2 18630AA000 WRENCH ASSEMBLY (LH SIDE) NOTE: Be careful not to damage the oil seal.
(B) ST1
7) Mark the mating positions of the left and right side retainers and the clutch housing.
MT-00658
8) Remove the differential side retainers from both sides. NOTE: When removing the side retainer, record how many times it was turned to remove. 9) Install new O-rings to the side retainers on both sides. 10) Attach the differential side retainers to both sides. NOTE: When attaching, turn the side retainer the same number of turns it took to remove, and align the marks. 11) Install the lock plate.
(A)
ST2
Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) NOTE: Be careful not to confuse the left and right side lock plates.
(A) MT-00657
(B)
(A) LH side (B) RH side
5) Inspect and adjust the hypoid gear backlash. <Ref. to 6MT-107, HYPOID GEAR BACKLASH, INSPECTION, Front Differential Assembly.> 6) Inspect and adjust the tooth contact. <Ref. to 6MT-98, ADJUSTMENT, Drive Pinion Shaft Assembly.>
MT-00659
(A) LH (B) RH
12) Remove any remaining liquid gasket from the clutch housing and adapter plate.
6MT-101

13) Apply liquid gasket to the clutch housing. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
C: DISASSEMBLY
1. DIFFERENTIAL CASE
1) Fix the differential assembly on a vise, and remove the hypoid driven gear. ST 18270KA020 SOCKET (E20)
MT-00532
14) Install the drive pinion shaft assembly. <Ref. to 6MT-94, INSTALLATION, Drive Pinion Shaft Assembly.> 15) Install the individual gear assemblies all at once. <Ref. to 6MT-65, INSTALLATION, Main Shaft Assembly.> 16) Install the transmission case. <Ref. to 6MT-60, INSTALLATION, Transmission Case.> 17) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 18) Install the transfer driven gear. <Ref. to 6MT55, INSTALLATION, Transfer Driven Gear.> 19) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 20) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 21) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
MT-00660
2) Using the ST, remove the roller bearing. ST 399527700 PULLER SET
ST
MT-00663
3) Using the ST, remove the roller bearing. ST 498077000 REMOVER
ST
MT-00665
4) Remove the differential case LH.
MT-01532
6MT-102

5) Remove the differential bevel gear and washer.

(B)
8) Remove differential bevel pinion and pinion shaft joint.
(A)
(A) MT-01533
(B)
MT-01536
(A) Differential bevel gear (B) Washer
(A) Differential bevel pinion (B) Pinion shaft joint
6) Using a magnet tool, etc., remove 3 straight pins.

(A)
9) Remove the differential bevel gear and washer.
2. SIDE RETAINER
(A)
(A)
MT-01534
(A) Straight pin
7) Remove 3 pinion shafts.
MT-00666
MT-01535
AT-00220
6MT-103

3) Remove the claw of ST1, and attach the claw of ST2. ST1 398527700 PULLER ASSY ST2 18760AA000 CLAW
ST1
D: ASSEMBLY
1. DIFFERENTIAL CASE
1) Install differential bevel gear and washer to the differential case RH. NOTE: Face the chamfered side of washer toward gear.
(A)
ST2 MT-01537
2) Install differential bevel pinion and pinion shaft joint.
(A)
MT-00668
(A) CLAW
(B)
4) Remove the bearing outer race from the side retainer, using the ST. ST1 398527700 PULLER ASSY ST2 18760AA000 CLAW
MT-01536
(A) Differential bevel pinion (B) Pinion shaft joint
ST1
3) Install 3 pinion shafts.
ST2
(A)
MT-00669
(A) Side retainer

MT-01535
6MT-104

4) Install 3 straight pins. NOTE: Make sure the straight pins are inserted completely.
(A)
7) Use the ST to attach bearings of differential cases RH and LH. ST1 398437700 INSTALLER ST2 398497701 SEAT CAUTION: Do not apply pressure in excess of 20 kN (2.0 ton, 2.2 US ton, 2.0 Imp ton).
(A)
(A)
NOTE: Always replace bearings and outer races as a set.

ST1
MT-01534
(A) Straight pin
5) Attach the differential bevel gear and washer. NOTE: Face the chamfered side of washer toward gear.
(B) ST2 MT-01538
8) Attach the hypoid driven gear to the differential case. ST 18270KA020 SOCKET (E20) Tightening torque: 69 Nm (7.0 kgf-m, 50.9 ft-lb)
(A) MT-01533
(A) Differential bevel gear (B) Washer
6) Install the differential case LH.
MT-00660
9) Inspect the backlash of the bevel pinion gear. <Ref. to 6MT-106, BEVEL PINION GEAR BACKLASH, INSPECTION, Front Differential Assembly.>
MT-01532
6MT-105

2. SIDE RETAINER
NOTE: Install the oil seal and O-ring of side retainer after the adjustment of backlash and tooth contact. 1) Install the bearing outer race to side retainer. 2) Using the ST, install the oil seal. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Use a new oil seal. Apply oil to the oil seal lips.
ST
E: INSPECTION
Repair or replace the differential in the following cases: If gears are damaged, seized, or are excessively worn. If differential case sliding surfaces are damaged, seized, or are excessively worn. If there is damage, rust or wear in the bearings or bearing locations. If the bearing does not rotate smoothly or an abnormal noise is emitted when turning.

Measure the backlash of the differential bevel pinion. If backlash is not within standard value, install a suitable washer to adjust. <Ref. to 6MT-108, ADJUSTMENT, Front Differential Assembly.> CAUTION: When measuring the backlash, hold the differential assembly in upright position.
AT-00226
3) Install the O-ring. NOTE: Use new O-rings.
NOTE: It is recommended that backlash be measured by 2 people. One person should push the differential bevel gear upward (differential case LH side), and the other person measure the backlash. Before measuring backlash, turn so that the gears will settle in their individual locations. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0.13 0.18 mm (0.0051 0.0071 in)
AT-00219
MT-01542
ST1 ST2
MT-01543
6MT-106


Inspect the hypoid gear backlash. Adjust if out of standard. <Ref. to 6MT-108, HYPOID GEAR BACKLASH, ADJUSTMENT, Front Differential Assembly.>

1) Check that the hypoid gear backlash is within the standard value. Adjust if out of standard. <Ref. to 6MT-108, HYPOID GEAR BACKLASH, ADJUSTMENT, Front Differential Assembly.> 2) Apply a thin uniform coat of lead-free red dye on the surfaces of 3 or 4 hypoid driven gear teeth.
5) Remove the drive pinion shaft assembly, and inspect the mating condition of the teeth. If tooth contact is not correct, perform adjustment. <Ref. to 6MT-98, ADJUSTMENT, Drive Pinion Shaft Assembly.> Correct tooth contact NOTE: In a no load condition, the tooth contact from the center to the toe side is 50-60% (While driving, the tooth contact will shift towards the heel side.).
(A)
(B)
MT-01401
MT-00652
3) Attach the drive pinion shaft assembly, and affix with 4 bolts. NOTE: Use old gaskets and washers to prevent the mating surfaces of the housing from becoming damaged. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 4) Turn the drive pinion shaft to the left and right for several turns.
6MT-107

F: ADJUSTMENT
1) Measure the backlash of the bevel pinion gear. <Ref. to 6MT-106, BEVEL PINION GEAR BACKLASH, INSPECTION, Front Differential Assembly.> 2) Disassemble the differential case. <Ref. to 6MT102, DIFFERENTIAL CASE, DISASSEMBLY, Front Differential Assembly.> 3) Select a washer from the following table, and assemble the differential case. <Ref. to 6MT-104, DIFFERENTIAL CASE, ASSEMBLY, Front Differential Assembly.> NOTE: If the backlash is excessive, select a thicker washer. If the backlash is too small, select a thinner washer.
Washer Part No. 803038021 803038022 803038023 803038024 803038025 Thickness mm (in) 0.950 (0.0374) 1.000 (0.0394) 1.050 (0.0413) 0.900 (0.0354) 1.100 (0.0433)

1) Attach the RH and LH side retainers. ST1 18630AA010 WRENCH COMPL RETAINER (RH SIDE) ST2 18630AA000 WRENCH ASSEMBLY (LH SIDE) NOTE: Twist in the RH side side retainer a little further than the LH side. WRENCH ASSEMBLY (499787000) can also be used. 2) Attach the drive pinion shaft assembly, and affix with 4 bolts. NOTE: Use old gaskets and washers to prevent the mating surfaces of the housing from becoming damaged. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 3) Using the ST, twist in the side retainer LH until it just contacts the drive pinion and hypoid driven gear. Loosen side retainer RH. ST1 18630AA010 WRENCH COMPL RETAINER (RH SIDE) ST2 18630AA000 WRENCH ASSEMBLY (LH SIDE) NOTE: WRENCH ASSEMBLY (499787000) can also be used. 4) Use the ST to turn the drive pinion shaft a few times. ST 18631AA000 HANDLE
ST
MT-00653
5) Repeat steps 3) and 4) until side retainer LH does not turn anymore. For side retainer RH, twist in until the inner race and outer race just comes into contact. This is the zero backlash state.
6MT-108

6) Mark the mating positions of the left and right side retainers and the clutch housing.

Regarding teeth contact conditions, refer to the drive pinion section. <Ref. to 6MT-107, TOOTH CONTACT OF HYPOID GEAR, INSPECTION, Front Differential Assembly.>
MT-00658
7) Turn the back side retainer LH by 3 notches, and screw in the side retainer RH by 3 notches. 8) Use the ST to fix the drive pinion shaft in place. ST 18621AA000 ADAPTER WRENCH
ST
MT-00674
9) Install the SUBARU genuine axle shaft to the front differential left and right sides. Part No. 38415AA000 Axle shaft 10) After turning the drive pinion shaft several turns, use the ST to measure the hypoid gear backlash. ST1 498255400 PLATE ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE Hypoid gear backlash: 0.13 0.18 mm (0.0051 0.0071 in)
ST3 ST2 ST1 MT-00675
11) If the backlash is out of specified range, turn the right and left side retainers to adjust. 12) Turn the RH side retainer by 1.25 notches or more.
6MT-109

22.Shifter Fork and Rod

A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the transmission case. <Ref. to 6MT58, REMOVAL, Transmission Case.> 8) Remove the individual gear assemblies. <Ref. to 6MT-64, REMOVAL, Main Shaft Assembly.>
C: DISASSEMBLY
NOTE: Discard the removed spring pin, and replace with a new part.
1. REVERSE SHIFTER FORK

1) Remove the reverse fork using the ST. ST 398791700 REMOVER
ST
MT-00680
2) Remove the reverse shifter arm using the ST. ST 398791700 REMOVER
B: INSTALLATION
1) Install the individual gear assemblies all at once. <Ref. to 6MT-65, INSTALLATION, Main Shaft Assembly.> 2) Install the transmission case. <Ref. to 6MT-60, INSTALLATION, Transmission Case.> 3) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 4) Install the transfer driven gear. <Ref. to 6MT-55, INSTALLATION, Transfer Driven Gear.> 5) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 6) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 7) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
ST
MT-00681
6MT-110

2. 1ST-2ND, 3RD-4TH SHIFTER FORK

1) Using the ST, remove the 3rd-4th shifter fork. ST 398791700 REMOVER
3. 5TH-6TH SHIFTER FORK

1) Using the ST, remove the 5th-6th shifter fork. ST 398791700 REMOVER
ST
ST
MT-00682
MT-00685
2) Using the ST, remove the 3rd-4th shifter arm. ST 398791700 REMOVER
2) Using the ST, remove the 5th-6th shifter arm. ST 398791700 REMOVER
ST
ST
MT-00683
MT-00686
3) Using the ST, remove the 1st-2nd shifter arm and 1st-2nd shifter fork. ST 398791700 REMOVER
(A) (B)
4. SHIFTER ARM SHAFT

Remove the selector arm using the ST. ST 398791700 REMOVER
ST
MT-00684 MT-01095
(A) 1st-2nd shifter arm (B) 1st-2nd shifter fork
6MT-111

5. STRIKING ROD
1) Remove the reverse interlock block and the interlock block from the striking rod.
(B) (A)
D: ASSEMBLY
1. REVERSE SHIFTER FORK
1) Using the ST, install the reverse fork. ST 398791700 REMOVER NOTE: Confirm that the reverse fork and rod are installed in the proper direction.
(A) (C)
MT-00688
(A) Reverse interlock block (B) Interlock block

(B)
2) Remove the reverse interlock arm using the ST. ST 398791700 REMOVER
(A) Reverse fork (B) Reverse rod (C) Spring pin
ST (A)
MT-00691
(B)
2) Using the ST, install the reverse arm. ST 398791700 REMOVER NOTE: Confirm that the reverse arm and rod are installed in the proper direction.
MT-00689
(A) Reverse interlock arm (B) Interlock arm
(C) (B)
3) Remove the interlock arm using the ST. ST 398791700 REMOVER

(A)
ST (A)
MT-00692
(A) Reverse arm (B) Reverse rod (C) Spring pin
MT-00690
(A) Interlock arm
6MT-112

2. 1ST-2ND, 3RD-4TH SHIFTER FORK

1) Using the ST, install the 1st-2nd shifter fork. ST 398791700 REMOVER NOTE: Make sure that the 1st-2nd shifter fork and rod are installed in the correct direction.
(C)
3) Using the ST, install the 3rd-4th shifter arm. ST 398791700 REMOVER NOTE: Make sure that the 3rd-4th shifter arm and rod are installed in the correct direction.
(A) (C)
(B) (B)
(A) MT-00695 MT-00693
(A) 1st-2nd shifter fork (B) 1st-2nd shifter rod (C) Spring pin
(A) 3rd-4th shifter rod (B) 3rd-4th shifter arm (C) Spring pin
2) Using the ST, install the 1st-2nd shifter arm. ST 398791700 REMOVER NOTE: Make sure that the 1st-2nd shifter arm and fork are installed in the correct direction.
(C) (A)
4) Attach the 3rd-4th fork rod to the 1st-2nd shifter arm.
(B) MT-00696
5) Using the ST, install the 3rd-4th shifter fork. ST 398791700 REMOVER
MT-00694
(A) 1st-2nd shifter fork (B) 1st-2nd shifter arm (C) Spring pin
NOTE: Make sure that the 3rd-4th shifter fork is installed in the correct direction.
(B)
(A)
MT-01737
(A) 3rd-4th shifter fork (B) Spring pin
6MT-113

3. 5TH-6TH SHIFTER FORK

1) Using the ST, install the 5th-6th shifter arm. ST 398791700 REMOVER NOTE: Make sure that the 5th-6th shifter arm and rod are installed in the correct direction.
(B) (C)
4. SHIFTER ARM SHAFT

Using the ST, install the selector arm. ST 398791700 REMOVER NOTE: Confirm that the selector arm and rod are installed in the proper direction.
(C)
(A)
(B)
(A) MT-00698 MT-01096
(A) 5th-6th shifter arm (B) 5th-6th shifter rod (C) Spring pin
(A) Selector rod (B) Selector arm (C) Spring pin
2) Using the ST, install the 5th-6th shifter fork. ST 398791700 REMOVER NOTE: Check that the 5th-6th shifter fork and arm are installed.
(C) (B)
5. STRIKING ROD
1) Using the ST, install the reverse interlock arm and interlock arm. ST 398791700 REMOVER NOTE: Confirm that the reverse interlock arm and rod are installed in the proper direction. Confirm that the interlock arm and rod are installed in the proper direction.
(C) (C) (A) (B)
(A)
MT-00699
(A) 5th-6th shifter fork (B) 5th-6th shifter arm (C) Spring pin (A) Reverse interlock arm (B) Interlock arm (C) Spring pin
MT-00701
6MT-114

2) Attach the reverse interlock block and interlock block to the striking rod. NOTE: Confirm that the reverse interlock block and interlock block are installed in the proper direction.
(B) (A)
F: ADJUSTMENT
1. 1ST-2ND FORK ROD SELECTION
NOTE: In the following conditions, perform the procedures below. Replacing the 1st and 2nd driven gear Replacing the 1st and 2nd synchro ring assembly Replacing the adapter plate Replacing the driven shaft Replacing the 1st-2nd hub and sleeve assemblies 1) Insert the drive pinion assembly into the adapter plate. NOTE: Confirm that the thrust bearing outer race has not been removed and the drive pinion is not lifted. 2) Set the height gauge to the adapter plate. Lower the height gauge indicator to the mating surface of the adapter plate and case, and set to zero points. ST 18853AA000 HEIGHT GAUGE
ST
MT-00688
(A) Reverse interlock block (B) Interlock block
E: INSPECTION
1) Check the shift shaft and shift rod for damage. Replace if damaged. 2) Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
MT-00582
MT-00583
3) Select the main shaft snap ring. <Ref. to 6MT77, ADJUSTMENT, Main Shaft Assembly.>
6MT-115

4) Measure B1 and B2 as shown in the figure.
6) Set the height gauge indicator upside down.
(A) B2 B1
MT-00979
MT-00703
5) Shift the 1st-2nd sleeve to the 1st driven gear side, push down to the stopper, and measure B1.
(A) Indicator
7) Shift the 1st-2nd sleeve to the 2nd driven gear side, push up on the stopper, and measure B2.
(B)
(A) (B) (A) MT-00702
(A) 1st driven gear (B) 1st-2nd sleeve
MT-00704
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 1st side end surface of the sleeve. Turn approximately 72 at a time, and measure the sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2)
(A) 2nd driven gear (B) 1st-2nd sleeve
(1)
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 2nd side end surface of the sleeve. The measurement is to be performed with 2 persons, while holding the sleeve straight. Turn approximately 72 at a time, and measure the sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2)
(1)
MT-00585
MT-00585
6MT-116

8) According to both of the measurements, calculate the neutral position of the 1st-2nd sleeve. From the following calculation, select a fork rod which matches the calculated value. Calculation: T = (B1 + B2) / 2 T: 1st-2nd sleeve center position B1: Height from the adapter plate end to the sleeve end, when shifted to 1st gear B2: Measured height from the adapter plate end to the sleeve end, when shifted to 2nd gear: +55 mm (2.17 in) NOTE: Attach the indicator upside down in comparison to the setting procedures for the 0 point. Add d1 [Value: 55 mm (2.17 in)] from the figure below to B2, and measure B2.
2. 3RD-4TH FORK ROD SELECTION

NOTE: In the following conditions, perform the procedures below. Replacing the main shaft Replacing the 3rd, and 3rd to 6th drive gear and bushing Replacing the 3rd, and 3rd to 6th synchro assemblies Replacing the 3rd-4th hub and sleeve assemblies 1) Insert the main shaft assembly into the adapter plate. 2) Set the height gauge to the adapter plate. Lower the height gauge indicator to the top surface of the snap ring groove, and set to the zero point on the upper side of the main rear bearing. ST 18853AA000 HEIGHT GAUGE
(A)
d1
MT-00705
T mm (in) 62.93 63.23 (2.4776 2.4894) 63.23 63.53 (2.4894 2.5012) 62.63 62.93 (2.4657 2.4776)
Lot No. (marking) 32801AA180 (1) 32801AA190 (none) 32801AA240 (3) (A) Ball bearing
MT-00706
NOTE: The height gauge will be set on the adapter plate during the measurement. Use a scraper to remove any gasket material remaining on the end face. During measurement, do not place the height gauge in the shaded area shown in the figure.
MT-00583
6MT-117

3) Use a height gauge to measure C1 and C2 as shown in the figure.
(1) Shift the 3rd-4th sleeve to the 4th gear side, push up on the stopper, and measure C2.
(A)
C2 C1 MT-00708
(A) 4th drive gear

(B)
(A)
MT-00707
(A) 3rd drive gear (B) 4th drive gear
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 4th side end surface of the sleeve. The measurement is to be performed with 2 persons, while holding the sleeve straight. Turn approximately 72 at a time, and measure the sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2)
(1)
MT-00585
(2) Set the height gauge indicator upside down.
(A)
MT-00710
(A) Indicator
6MT-118

(3) Shift the 3rd-4th sleeve to the 3rd drive gear side, push down to the stopper, and measure C1.
(A)
4) According to both of the measurements, calculate the neutral position of the 3rd-4th sleeve. From the following calculation, select a fork rod which matches the calculated value. Calculation: T = (C1 + C2) / 2 T: 3rd-4th sleeve center position C1: Measured depth from the main shaft rear bearing snap ring groove to the sleeve end, when shifted to 3rd gear: +55 mm (2.17 in) C2: Measured depth from the main shaft rear bearing snap ring groove to the sleeve end, when shifted to 4th gear NOTE: Attach the indicator upside down in comparison to the setting procedures for the 0 point. Add d1 [Value: 55 mm (2.17 in)] from the figure below to C1, and measure C1.
MT-00711
(A) 3rd drive gear
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 3rd side end surface of the sleeve. Turn approximately 72 at a time, and measure the sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2)
d1
MT-00705 (1)
mm (in)
Lot No. (marking) M.SFT M.SFT M.SFT Snap ring Snap ring Snap ring 805072010 805072011 805072012 [t = 1.65 mm [t = 1.95 mm [t = 2.25 mm (0.065 in)] (0.077 in)] (0.089 in)]
MT-00585
137.22 137.52 32809AA171 32809AA181 32809AA191 (5.4024 5.4142) (none) (2) (4) 137.52 137.82 32809AA161 32809AA171 32809AA181 (5.4142 5.4260) (1) (none) (2) 137.82 138.12 32809AA141 32809AA161 32809AA171 (5.4260 5.4379) (3) (1) (none) T = Thickness
6MT-119

3. 5TH-6TH FORK ROD SELECTION

NOTE: In the following conditions, perform the procedures below. Replacing the main shaft 3rd to 6th drive gear and bushing replacement Replacing the 3rd to 6th synchro ring assemblies Replacing the 3rd-4th hub and sleeve assemblies Replacing the 5th-6th hub and sleeve assemblies 1) Insert the main shaft assembly into the adapter plate. 2) Set the height gauge to the adapter plate. Lower the height gauge indicator to the upper face of the snap ring groove or the upper side of the main rear bearing. Set to 0 point. ST 18853AA000 HEIGHT GAUGE
(A)
3) Use a height gauge to measure D1 and D2 as shown in the figure.
D2 D1 (B)
(A)
MT-00712
(A) 5th main gear (B) 6th main gear

MT-00706
(A) Ball bearing
NOTE: The height gauge will be set on the adapter plate during the measurement. Use a scraper to remove any gasket material remaining on the end face. During measurement, do not place the height gauge in the shaded area shown in the figure.
MT-00583
6MT-120

(1) Shift the 5th-6th sleeve to the 6th main gear side, push up on the stopper, and measure D2.
(3) Shift the 5th-6th sleeve to the 5th main gear side, push down to the stopper, and measure D1.
(A)
(A)
MT-00713
MT-00714
(A) 6th main gear
(A) 5th main gear
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 6th side end surface of the sleeve. The measurement is to be performed with 2 persons, while holding the sleeve straight. Turn approximately 72 at a time, and measure the sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2)
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 5th side end surface of the sleeve. Turn approximately 72 at a time, and measure the sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2)
(1) (1)
MT-00585 MT-00585
(2) Set the height gauge indicator upside down.
(A)
MT-00710
(A) Indicator
6MT-121

4) According to both of the measurements, calculate the neutral position of the 5th-6th sleeve. From the following calculation, select a fork rod which matches the calculated value. Calculation: T = (D1 + D2) / 2 T: 5th-6th sleeve center position D1: Measured length from the shaft rear bearing snap ring groove to the sleeve groove end, when shifted to 5th gear [Value: +55 mm (2.17 in)] D2: Measured length from the main shaft rear bearing snap ring groove to the sleeve groove end, when shifted to 6th gear NOTE: Attach the indicator upside down in comparison to the setting procedures for the 0 point. Add d1 [Value: 55 mm (2.17 in)] from the figure below to D1, and measure D1.
4. REVERSE FORK ROD SELECTION

NOTE: In the following conditions, perform the procedures below. Replacing the reverse idler gear Replacing the reverse idler gear No. 2 Replacing the adapter plate Replacing the base 1) Insert the reverse idler gear assembly into the adapter plate. 2) Tighten the base COMPL attachment bolts. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
d1 MT-00546
MT-00705
mm (in)
Lot No. (marking) M.SFT M.SFT M.SFT Snap ring Snap ring Snap ring 805072010 805072011 805072012 [t = 1.65 mm [t = 1.95 mm [t = 2.25 mm (0.065 in)] (0.077 in)] (0.089 in)]
3) Set the height gauge to the adapter plate. Lower the height gauge indicator to the mating surface of the adapter plate and case, and set to zero points. ST 18853AA000 HEIGHT GAUGE
ST
64.12 64.42 32945AA021 32945AA031 32945AA041 (2.5244 2.5362) (none) (2) (4) 64.42 64.72 32945AA011 32945AA021 32945AA031 (2.5362 2.5480) (1) (none) (2) 64.72 65.02 32945AA001 32945AA011 32945AA021 (2.5480 2.5598) (3) (1) (none) T = Thickness
MT-00582
MT-00583
6MT-122

4) Press fit the reverse sleeve to the reverse idler gear No. 2, and measure T.
5) Calculate the neutral position of the reverse sleeve according to the measurement. From the following calculation, select a fork rod which matches the calculated value. Calculation: T + 4.8 mm (0.189 in)
T + 4.8 mm (0.189 in) mm (in) 33.50 33.80 (1.3189 1.3307) 33.80 34.10 (1.3307 1.3425) 34.10 34.40 (1.3425 1.3543) T = Thickness Lot No. (marking) 32816AA110 (1) 32816AA130 (none) 32816AA140 (2)
(A) T
MT-00715
(A) Reverse idler gear No. 2
(A)
MT-00716
(A) Reverse idler gear No. 2
NOTE: Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the end face of the reverse sleeve side. Turn approximately 72 at a time, and measure the sleeve in 5 locations. Round down the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2)
(1)
MT-00585
6MT-123
Clutch Housing
23.Clutch Housing
A: REMOVAL
1) Remove the manual transmission assembly from the vehicle. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Prepare the transmission for overhaul. <Ref. to 6MT-37, Preparation for Overhaul.> 3) Remove the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, REMOVAL, Neutral Position Switch.> <Ref. to 6MT39, REMOVAL, Back-up Light Switch.> 4) Remove the extension case. <Ref. to 6MT-43, REMOVAL, Extension Case.> 5) Remove the transfer driven gear. <Ref. to 6MT55, REMOVAL, Transfer Driven Gear.> 6) Remove the center differential. <Ref. to 6MT-57, REMOVAL, Center Differential.> 7) Remove the transmission case. <Ref. to 6MT58, REMOVAL, Transmission Case.> 8) Remove the individual gear assemblies. <Ref. to 6MT-64, REMOVAL, Main Shaft Assembly.> 9) Remove the drive pinion shaft assembly. <Ref. to 6MT-94, REMOVAL, Drive Pinion Shaft Assembly.> 10) Remove the front differential assembly. <Ref. to 6MT-100, REMOVAL, Front Differential Assembly.>
B: INSTALLATION
1) Install the pitching stopper bracket. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb) 2) Install the front differential assembly. <Ref. to 6MT-101, INSTALLATION, Front Differential Assembly.> 3) Install the drive pinion shaft assembly. <Ref. to 6MT-94, INSTALLATION, Drive Pinion Shaft Assembly.> 4) Install the individual gear assemblies all at once. <Ref. to 6MT-65, INSTALLATION, Main Shaft Assembly.> 5) Install the transmission case. <Ref. to 6MT-60, INSTALLATION, Transmission Case.> 6) Install the center differential. <Ref. to 6MT-57, INSTALLATION, Center Differential.> 7) Install the transfer driven gear. <Ref. to 6MT-55, INSTALLATION, Transfer Driven Gear.> 8) Install the extension case. <Ref. to 6MT-43, INSTALLATION, Extension Case.> 9) Install the neutral position switch, back-up light switch and harness. <Ref. to 6MT-41, INSTALLATION, Neutral Position Switch.> <Ref. to 6MT-39, INSTALLATION, Back-up Light Switch.> 10) Install the manual transmission assembly to the vehicle. <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
C: DISASSEMBLY
1) Remove the clutch release bearing guide.
MT-01383
MT-01381
6MT-124
Clutch Housing
D: ASSEMBLY
1) Attach the oil seal to the clutch housing, being careful not to damage the seal. NOTE: Use a new oil seal. ST 18657AA020 OIL SEAL INSTALLER
ST MT-01382
2) Install the clutch release bearing guide. Tightening torque: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
MT-01383
E: INSPECTION
1) Check to make sure there is no damage or cracks on the clutch housing. If there is excessive damage, replace the clutch housing. 2) Inspect the clutch housing for transmission gear oil leakage. If any oil leaks are found, repair or replace the applicable part.
6MT-125


A: INSPECTION
Symptom 1. Gears are difficult to engage NOTE: If it is difficult to shift, there are 2 possible causes. One is a defective gear shift system and the other is defective transmission. However, if the operation is heavy and engagement of the gears is difficult, a defective clutch function may also be responsible. Check whether the clutch is correctly functioning, before checking the gear shift system and transmission. 2. Gear slip-out Gear slips out when coasting on rough road. Gear slips out during acceleration. Possible cause (a) Worn, damaged or burred chamfer at internal spline of the sleeve (b) Gear spline wear, damage, dents (c) Worn or scratched bushings (d) Incorrect contact or wear between synchronizer ring and gear cone Replace. Replace. Replace. Repair or replace. Corrective action
(a) Defective pitching stopper (b) Loose engine mounting bolts (c) Worn fork shifter, broken shifter fork rail spring (d) Worn or damaged ball bearing (e) Large clearance between splines of synchronizer hub and synchronizer sleeve (f) Worn in the synchronizer hub chamfer angle (g) Worn 1st driven gear, needle bearing and race (h) Worn 2nd driven gear, needle bearing and race (i) Worn 3rd drive gear and bushing (j) Worn 4th drive gear and bushing (k) Worn 5th drive gear and bushing (l) Worn 6th drive gear and bushing (m) Worn reverse idler gear and bushing (a) Insufficient or improper lubrication
Adjust. Tighten or replace. Replace. Replace. Replace.
Replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace.
3. Noise emitted from transmission NOTE: If a noise is heard when the vehicle is parked with its engine idling and ceases when the clutch is disengaged, it may be considered that the noise is coming from the transmission.
Replenish the specified amount of designated oil or replace. (b) Worn or damaged gears and bearings Replace. NOTE: If the trouble is only wear of the gear teeth surfaces, only a high whirring noise will occur at high speeds, but if any part is broken, rhythmical clicking sounds will be heard even at low speeds.
6MT-126

2. DIFFERENTIAL
Symptom 1. Broken differential (case, gear, bearing, etc.) NOTE: Noise will occur, and eventually the differential will not be able to operate due to broken pieces obstructing the gear revolution. Possible cause (a) Insufficient or improper oil Corrective action Disassemble the differential and replace broken components. At the same time check other components for any trouble, and replace if necessary. Readjust the preload and backlash of the bearing, and the contact surface of gear. Adjust. Adjust. Tighten. Replenish the specified amount of designated oil or replace. Check the tooth contact. Replace as a set. Readjust the bearing preload. Readjust the backlash of the hypoid driven gear to drive pinion, and check the tooth contact. Replace.
(b) Use of vehicle under severe conditions such as excessive load and improper use of the clutch (c) Improper adjustment of taper roller bearing (d) Improper adjustment of the drive pinion and the hypoid driven gear (e) Loose hypoid driven gear clamp bolts (a) Insufficient oil (b) Improper adjustment of hypoid driven gear and drive pinion (c) Worn teeth of hypoid driven gear and drive pinion (d) Loose roller bearing
2. Differential and hypoid gear noises Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of trouble. However, noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the following four kinds of noises. Gear noise when driving: If noise increases as the vehicle speed increases, it may be due to insufficient gear oil, incorrect gear engagement, damaged gears, etc. Gear noise when coasting: Damaged gears due to misadjusted bearings and incorrect shim adjustment Bearing noise when driving or coasting: Cracked, broken or damaged bearings.
(e) Distorted hypoid driven gear or differential case
6MT-127

6MT-128
General Description
CLUTCH SYSTEM
A: SPECIFICATION
Model Transmission type Clutch cover Type Diaphragm set load Facing material O.D. I.D. thickness mm (in) Spline outer diameter Clutch disc Depth of rivet head mm (in) 2.5 L Non-turbo 5MT Push type N (kgf, lbf) Flywheel side Clutch cover side mm (in) Flywheel side Clutch cover side Limit of sinking mm (in) 5,688 (580, 1,279) Woven 225 150 3.5 (8.86 5.91 0.138) 25.2 (0.992) 1.4 1.9 (0.055 0.075) 1.7 2.2 (0.067 0.087) 1.7 2.2 (0.067 0.087) 0.3 (0.012) 0.7 (0.028) at R = 110 (4.33) 1.6 Grease-packed self-aligning 130 135 (5.12 5.31) 135 140 (5.31 5.51) 4 13 (0.16 0.51) Flexible 2.5 L Turbo 6MT Pull type 7,430 (758, 1,671) Woven 230 155 3.2 (9.06 6.10 0.126) 230 155 3.5 (9.06 6.10 0.138) 25.2 (0.992) 1.4 1.9 (0.055 0.075) 1.7 2.2 (0.067 0.087) 0.3 (0.012) 0.7 (0.028) at R = 110 (4.33) 1.7 Grease-packed self-aligning 130 135 (5.12 5.31) 4 13 (0.16 0.51) Conventional 230 155 3.2 (9.06 6.10 0.126) 230 155 3.5 (9.06 6.10 0.138) 7,450 (760, 1,675) 2.5 L Turbo
Deflection limit Clutch release lever ratio Release bearing Full stroke Clutch pedal Free play Flywheel Type Model Transmission type Clutch cover Type Diaphragm set load Facing material O.D. I.D. thickness mm (in) Spline outer diameter Clutch disc Depth of rivet head mm (in)
mm (in) mm (in)
N (kgf, lbf) Flywheel side Clutch cover side mm (in) Flywheel side Clutch cover side Limit of sinking mm (in)
Deflection limit Clutch release lever ratio Release bearing Full stroke Clutch pedal Free play Flywheel Type
mm (in) mm (in)
CL-2
General Description
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY
5MT non-turbo model
(1)
(4) (5) (3) (2)
T1
(6) T2
(5)
T1 (7) (8) (9)
CL-00496
(1) (2) (3) (4) (5)
Dust cover Lever spring Pivot Release lever Clip
(6) (7) (8) (9)
Release bearing Clutch cover Clutch disc Flexible flywheel
CL-3
General Description
CLUTCH SYSTEM
5MT turbo model

(1)
(2) (4)
T2 (5) T1 (3)
T1 (6) (7) (8) CL-00508
(1) (2) (3) (4)
Dust cover Lever spring Pivot Release lever
(5) (6) (7) (8)
Release bearing Clutch cover Clutch disc Flexible flywheel
CL-4
General Description
CLUTCH SYSTEM
6MT model
(1)
(2)
T3
(5)
(3)
(4)
T2 T1
(6) (7) (8) CL-00501
(1) (2) (3) (4)
Dust cover Release lever Release shaft Plug
(5) (6) (7) (8)
Release bearing Clutch cover Clutch disc Conventional flywheel
CL-5
General Description
CLUTCH SYSTEM
2. CLUTCH PIPE AND HOSE
T2 (4) T4
(1)
(5) (2) (3) T3 T3 (6) (10) (5) (6) (6) T5 T1 T3
T5 T1
T3
(9) (7) (8) T1 T6 T1
(5)
CL-00650
(1) (2) (3) (4) (5) (6) (7)
Master cylinder ASSY Clutch pipe Clamp Bracket Clutch hose Washer Operating cylinder (5MT non-turbo model)
(8) (9) (10)
Operating cylinder (5MT turbo model) Operating cylinder (6MT turbo model) Clip
Tightening torque:Nm (kgf-m, ft-lb) T1: 7.8 (0.8, 5.8) T2: 15 (1.5, 11.1) T3: 18 (1.8, 13.3) T4: 25 (2.5, 18.4) T5: 37 (3.8, 27.3) T6: 41 (4.2, 30.2)
CL-6
General Description
CLUTCH SYSTEM
3. MASTER CYLINDER
(1) (11) (2)
(12)
T2
(10)
(3) (4) (8) (9)
(13)
(5) (7) (6) T3
T1
CL-00559
(1) (2) (3) (4) (5) (6)
Reservoir cap Reservoir tank Oil seal Straight pin Master cylinder Clutch damper
(7) (8) (9) (10) (11) (12)
Gasket Return spring Piston Push rod ASSY Piston stop ring Seat
(13)
Bleeder screw
Tightening torque:Nm (kgf-m, ft-lb) T1: 7.8 (0.8, 5.8) T2: 10 (1.0, 7.4) T3: 46.6 (4.8, 34.4)
CL-7
General Description
CLUTCH SYSTEM
4. OPERATING CYLINDER
5MT non-turbo model
T (6)
(3) (2)
(1)
(4)
(5)
CL-00503
(1) (2) (3)
Push rod Boot Piston
(4) (5) (6)
Piston spring Operating cylinder Bleeder screw
CL-8
General Description
CLUTCH SYSTEM
5MT turbo model

T (6)
(3) (2)
(1)
(4)
(5)
CL-00504
(1) (2) (3)
Push rod Boot Piston
(4) (5) (6)
Piston spring Operating cylinder Bleeder screw
CL-9
General Description
CLUTCH SYSTEM
5. CLUTCH PEDAL
(7) (3) (21) T2 T1 (20) (10) (4)
T2 (2) (19) T2 (18) (10) (17) T1 (22) (1) T1 (13) (12) (13) (2) (2) (16) (15) (14) (7) (11) (10) (1) (6) (5) (1) (4) (2)
(7)
(8) (9) CL-00625
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Stopper Bushing Spring pin Snap pin Brake pedal pad Brake pedal Clevis pin Clutch pedal pad Clutch pedal
(10) (11) (12) (13) (14) (15) (16) (17) (18)
Bushing C Clutch clevis pin Assist rod A Clip Assist spring Assist bushing Assist rod B Clutch switch (Cruise control) Stop light switch
(19) (20) (21) (22)
Pedal bracket Clutch master cylinder bracket Lever Clutch switch (Clutch start)
CL-10
General Description
CLUTCH SYSTEM
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine fluid, grease etc. or equivalent. Do not mix fluid, grease, etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Apply grease onto sliding or revolving surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation. Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise. Keep fluids away from the vehicle body. If any fluid contacts the vehicle body, immediately flush the area with water.
CL-11
General Description
CLUTCH SYSTEM
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 498497100 DESCRIPTION CRANKSHAFT STOPPER REMARKS Used for stopping rotation of the flywheel.
ST-498497100
499747100
CLUTCH DISC GUIDE
Used when installing the clutch disc to the flywheel.
ST-499747100
2. GENERAL TOOL
TOOL NAME Circuit tester Dial gauge Depth gauge REMARKS Used for measuring resistance, voltage and ampere. Used for measuring clutch disc run-out. Used for measuring clutch disc wear.
CL-12
Clutch Disc and Cover

CLUTCH SYSTEM
2. Clutch Disc and Cover

A: REMOVAL
NOTE: The illustration below is for a 5MT non-turbo model. However, perform the same procedures for models other than 5MT non-turbo model as well. 1) Remove the transmission assembly from vehicle body. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Insert the ST on the flywheel. ST 499747100 CLUTCH DISC GUIDE
(A)
B: INSTALLATION
NOTE: The illustration below is for a 5MT non-turbo model. However, perform the same procedures for models other than 5MT non-turbo model as well. 1) Insert the ST into the clutch disc and attach to the flywheel by inserting the ST end into pilot bearing. NOTE: When installing the clutch disc, be careful to attach in the correct direction. ST 499747100 CLUTCH DISC GUIDE
ST
(A)
ST CL-00011 CL-00012
(A) Clutch cover
(A) Flywheel side
3) Remove the clutch cover and clutch disc. NOTE: Take care not to allow oil to touch the clutch disc face. Do not disassemble the clutch cover or clutch disc.
CL-13

CLUTCH SYSTEM
2) Install the clutch cover to the flywheel and tighten the bolts to the specified torque. NOTE: When installing the clutch cover to the flywheel, position the clutch cover so that the distance between unbalance marks ( paint marks) is at least 120. (The unbalance mark indicates the direction of residual unbalance.) Note the front and rear of the clutch disc when installing. Temporarily tighten the bolts by hand. Each bolt should be tightened to the specified torque in a crisscross order. Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
C: INSPECTION
NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
1. CLUTCH DISC
1) Facing wear: Measure the depth from the facing surface to the rivet head. Replace if the face is worn locally or worn down to less than the specified value. Depth to rivet head: Limit of sinking 0.3 mm (0.012 in) NOTE: Do not wash the clutch disc with any type of cleaning fluid.
(A) CL-00014 (3) (1)
(5) (6)
2) Hardened facing Replace the clutch disc. 3) Oil soakage on facing Replace the clutch disc and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other locations for oil leakage.
ST CL-00013 (A)
(2)
(4)
(A) Unbalance mark (paint)
3) Remove the ST. ST 499747100 CLUTCH DISC GUIDE 4) Install the transmission assembly. <Ref. to 5MT27, INSTALLATION, Manual Transmission Assembly.> <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
(A) Clutch facing
CL-00015
CL-14

CLUTCH SYSTEM
4) Deflection on facing: If deflection exceeds the specified value at the outer circumference of the facing, replace the clutch disc. ST 499747100 CLUTCH DISC GUIDE Limit for deflection: 0.7 mm (0.028 in) at R = 110 mm (4.33 in)
2. CLUTCH COVER
NOTE: Visually check the following items without disassembling, and replace or repair if defective. 1) Loose thrust rivet 2) Damaged or worn bearing contact area at the center of diaphragm spring
(A)
ST
(B)
CL-00016
CL-00018
5) If there is spline wear, loose rivets, failed damper springs, etc., replace the clutch disc.
(A) Thrust rivet (B) Diaphragm spring
3) Damaged or worn disc contact surface of the pressure plate 4) Loose strap plate installation area 5) Worn diaphragm sliding area
(A)
CL-00017
(A) Spline (B) Rivet (C) Damper spring
(B) CL-00177
(A) Pressure plate (B) Strap plate
CL-15
Flywheel
CLUTCH SYSTEM
3. Flywheel
A: REMOVAL
1) Remove the transmission assembly. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Remove the clutch cover and clutch disc. <Ref. to CL-13, REMOVAL, Clutch Disc and Cover.> 3) Using the ST, remove the flywheel. ST 498497100 CRANKSHAFT STOPPER
B: INSTALLATION
1) Install the flywheel and ST. ST 498497100 CRANKSHAFT STOPPER
ST
CL-00020
2) Tighten the flywheel mounting bolts to the specified torque. NOTE: Tighten the flywheel attachment bolts gradually. Each bolt should be tightened to the specified torque in crisscross order.
CL-00019
(A) ST
(A) Flywheel
(5) (3) (8) (2)
(1) (7) (4) (6)
CL-00021
3) Install the clutch disc and cover. <Ref. to CL-13, INSTALLATION, Clutch Disc and Cover.> 4) Install the transmission assembly. <Ref. to 5MT27, INSTALLATION, Manual Transmission Assembly.> <Ref. to 6MT-34, INSTALLATION, Manual Transmission Assembly.>
CL-16
Flywheel
CLUTCH SYSTEM
C: INSPECTION
NOTE: The illustration below is for a Turbo model. However, perform the same procedures for the Non-turbo model. CAUTION: Since this bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or any solvents. 1) If there is damage or defectiveness in the facing sliding surface or ring gear, replace the flywheel.
(B)
(A) CL-00366
(A) Flywheel (B) Ring gear
2) Smoothness of rotation Rotate the ball bearing while applying pressure in the thrust direction. 3) If noise or excessive play is noted, replace the flywheel.
CL-17
Release Bearing and Lever

CLUTCH SYSTEM
4. Release Bearing and Lever

A: REMOVAL
1. 5MT MODEL
1) Remove the transmission assembly from vehicle body. <Ref. to 5MT-24, REMOVAL, Manual Transmission Assembly.> 2) Remove the two clips from the release lever and remove the release bearing. (Non-turbo model) CAUTION: Be careful not to deform the clips. 3) Remove the release bearing from the clutch release lever. (Turbo model) 4) Remove the dust cover.
2. 6MT MODEL
1) Remove the transmission assembly from vehicle body. <Ref. to 6MT-32, REMOVAL, Manual Transmission Assembly.> 2) Remove the release lever from the transmission. 3) Install the release bearing to the engine side. 4) Using a flat tip screwdriver, remove the release bearing from the clutch cover.
(A)
CL-00025
(A) Release bearing

(A)
(B) CL-00023
(A) Release lever (B) Dust cover
5) Remove the lever spring from the pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever.
(B)
(A) CL-00024
(A) Release lever (B) Screwdriver
CL-18

CLUTCH SYSTEM
B: INSTALLATION
1. 5MT MODEL
NOTE: Apply the specified grease to lubricate the following points before installation. Contact surface of lever and pivot Contact surface of lever and bearing Transmission main shaft spline (Use grease containing molybdenum disulfide.) 1) While pushing the release lever to the pivot and twisting it to both sides, fit the lever spring onto the raised portion of the pivot. NOTE: Apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of the release lever and operating cylinder. Observing from the main case hole, check that the lever spring is installed securely.
(A)
2. 6MT MODEL
1) Attach the release bearing to the transmission. 2) Insert the release lever into the release bearing tab.
(A)
(B)
ME-00052
(A) Release lever (B) Release bearing
3) Apply grease to splines. Grease: NICHIMOLY N-130
CL-00026
(A) Release lever
2) Install the release bearing and fasten it with two clips. (Non-turbo model) 3) Install the release bearing. (Turbo model) 4) Install the dust cover.
(A)
(A) CL-00341 (B) CL-00023
(A) Spline
(A) Release lever (B) Dust cover
5) Check the bearing for smooth movement by operating the release lever. 6) Install the transmission assembly. <Ref. to 5MT27, INSTALLATION, Manual Transmission Assembly.>
CL-19

CLUTCH SYSTEM
4) Insert the release shaft into the release lever. NOTE: Make sure the cut portion of the release shaft comes into contact with the spring pin.
(B) (C) (A)
C: INSPECTION
1. RELEASE BEARING
NOTE: Since this bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or any other solvent when servicing the clutch. 1) Check the bearing for smooth movement by applying force to the bearing in the radial direction. Radial direction stroke: 1.6 mm (0.063 in) 5MT model
CL-00030
(A) Release lever (B) Release shaft (C) Spring pin
5) Tighten the plugs. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb)
(A)
CL-00032
(A) Bearing case
6MT model
(A)
CL-00031
6) Check the release bearing and release lever for smooth movement by operating the release lever. 7) Install the transmission assembly. <Ref. to 6MT34, INSTALLATION, Manual Transmission Assembly.>
CL-00527
(A) Bearing case
CL-20

CLUTCH SYSTEM
2) While applying force to the bearing in the rotational direction, check the bearing for smooth rotation. 5MT model
2. RELEASE LEVER
5MT model Check the pivot portion of the lever and the contact area with the release bearing case for wear.
(A)
(B)
(A)
(C)
CL-00160
CL-00034
(A) Bearing case
6MT model
(A) Clutch release lever (B) Pivot (C) Clutch release bearing
(A)
6MT model Check the release shaft of the lever and the contact area with the release bearing case for wear.
(A)
CL-00581
(B) (C)
(A) Bearing case
3) Check for wear and damage at the bearing case surface in contact with the lever.
(A) Release lever (B) Release shaft (C) Release bearing
CL-00645
CL-21
Operating Cylinder
CLUTCH SYSTEM
5. Operating Cylinder
A: REMOVAL
1) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 3) Disconnect the clutch hose from the operating cylinder. CAUTION: Cover the hose joint to prevent the clutch fluid from flowing out. Do not loosen or remove the cap bolts. 5MT model NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
(A)
4) Remove the operating cylinder from the transmission. 5MT model NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
MT-01220
6MT model
(A)
(B)
CL-00441
CL-00367
(A) Operating cylinder (A) Clutch hose (B) Operating cylinder
6MT model
(C) (B)
(A)
CL-00420
(A) Clutch hose (B) Operating cylinder (C) Cap bolt
CL-22
Operating Cylinder
CLUTCH SYSTEM
B: INSTALLATION
1. 5MT MODEL
1) Install in the reverse order of removal. NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model. Before installing the operating cylinder, apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of the release lever and operating cylinder. Tightening torque: T1: 18 Nm (1.8 kgf-m, 13.3 ft-lb) T2: 37 Nm (3.8 kgf-m, 27.3 ft-lb)
T2
2. 6MT MODEL
1) Install in the reverse order of removal. NOTE: Before installing the operating cylinder, apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of the release lever and operating cylinder. Tightening torque: T1: 18 Nm (1.8 kgf-m, 13.3 ft-lb) T2: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
T1
T1
T2
CL-00442
T2
CL-00368
2) After bleeding air from the operating cylinder, ensure that the clutch operates properly. <Ref. to CL-30, Clutch Fluid Air Bleeding.>
NOTE: Be sure to install the clutch hose with the mark side facing upward. Be careful not to twist the clutch hose during installation.
(C) (B) (A)

CL-00443
(A) Mark (B) Clutch hose (C) Operating cylinder
2) After bleeding air from the operating cylinder, ensure that the clutch operates properly. <Ref. to CL-30, Clutch Fluid Air Bleeding.>
CL-23
Operating Cylinder
CLUTCH SYSTEM
C: DISASSEMBLY
1) Remove the boots and push rod assembly. NOTE: Only 5MT model can be disassembled. The illustration below is for a Non-turbo model.
D: ASSEMBLY
NOTE: During assembly, apply hydraulic oil to all parts. Recommended brake fluid FMVSS No. 116, fresh DOT3 brake fluid 1) Install the piston spring onto the piston. NOTE: Only 5MT model can be assembled. The illustration below is for a Non-turbo model.
CL-00457
2) Apply compressed air through clutch hose attaching port. NOTE: Face the piston port down and place a piece of wood underneath to prevent the piston from popping out.
CL-00459
2) Insert piston to the operating cylinder. 3) Install push rod to the boot. 4) Install boot and push rod to the operating cylinder. NOTE: The illustration below is for a Non-turbo model.
CL-00458
3) Separate the piston and piston spring. NOTE: The illustration below is for a Non-turbo model.
CL-00457
E: INSPECTION
1) Check the operating cylinder for damage. If operating cylinder is damaged, replace it. 2) Check the operating cylinder for fluid leakage or damage on the boot. If any leakage or damage is found, replace the operating cylinder.
CL-00459
CL-24
Master Cylinder
CLUTCH SYSTEM
6. Master Cylinder
A: REMOVAL
1) Thoroughly drain the brake fluid from the reservoir tank. 2) Remove the snap pin and clevis pin, and then separate the push rod of the master cylinder from clutch pedal.
(A) (B) (D) (C)
B: INSTALLATION
1) Install the master cylinder to the vehicle body, and connect the clutch pipe to the master cylinder. NOTE: Check that the pipe is routed properly. Tightening torque: T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb) T2: 18 Nm (1.8 kgf-m, 13.3 ft-lb)
T2 T1 CL-00042
(A) (B) (C) (D)
Clevis pin Snap pin Push rod Lock nut
CL-00561
2) Connect the push rod of the master cylinder to the clutch pedal, and install the clevis pin and snap pin. NOTE: Apply grease to the clevis pin.
(A)
3) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 4) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 5) Remove the clutch pipe from the master cylinder. 6) Remove the master cylinder and reservoir tank as a unit. CAUTION: Be careful not to spill the brake fluid. Brake fluid spilled on the vehicle body will harm the paint surface; if spilled, wash off with water immediately and wipe off.
(A)
(B)
(C)
CL-00045
(A) Clevis pin (B) Snap pin (C) Push rod
(B)
3) After bleeding air from the clutch system, ensure that the clutch operates properly. <Ref. to CL-30, Clutch Fluid Air Bleeding.> 4) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 5) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.>
CL-00152
(A) Master cylinder ASSY (B) Clutch pipe
CL-25
Master Cylinder
CLUTCH SYSTEM
C: DISASSEMBLY
1) Remove the straight pin and reservoir tank.
D: ASSEMBLY
1) Install the clutch damper. Tightening torque: 46.6 Nm (4.8 kgf-m, 34.4 ft-lb) 2) Apply a coat of grease to the contact surfaces of the push rod and piston before installation. Grease: SILICONE GREASE G40M (Part No. 004404003)
CL-00562
(A)
(B)
(A) Reservoir tank (B) Straight pin

(A) CL-00564
3) Assemble in the reverse order of disassembly. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb)
(B) CL-00612
E: INSPECTION
If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring, gasket, clutch damper, seat or hose, replace the faulty part.
(C) (B) (A) (A) (D) (G)
(A) Oil seal (B) Master cylinder
3) Move the seat towards the rear.
(F) (B) CL-00513
(E) CL-00565
(A) Seat (B) Master cylinder
4) Remove the snap ring. CAUTION: When removing the piston stop ring, be careful to prevent the rod, washer, piston and return spring from coming out. 5) Remove the clutch damper.
(A) (B) (C) (D) (E) (F) (G)
Master cylinder body Return spring Piston Stop ring Push rod ASSY Clutch damper Seat
CL-26
Clutch Pipe and Hose

CLUTCH SYSTEM
7. Clutch Pipe and Hose

A: REMOVAL
1) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 3) Drain the clutch fluid. <Ref. to CL-29, Clutch Fluid.> 4) Disconnect the clutch pipe from the clutch hose and master cylinder. 5) Pull out the clamp, then remove the clutch hose from the bracket.
(A)
B: INSTALLATION
Install in the reverse order of removal. NOTE: Bleed air from the clutch fluid. <Ref. to CL-30, Clutch Fluid Air Bleeding.> 5MT model Tightening torque: T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb) T2: 18 Nm (1.8 kgf-m, 13.3 ft-lb) T3: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T1 T1
(A) T3 (B) T2 (B) (C) CL-00057 T2 (C) (F)
(A) Clamp (B) Clutch hose
6) Disconnect the hose from the operating cylinder. 7) Remove the bracket.
(D) (E) CL-00651
(A) (B) (C) (D) (E) (F)
Clutch pipe Clip Clutch hose (Non-turbo model) Operating cylinder (Non-turbo model) Operating cylinder (Turbo model) Clutch hose (Turbo model)
CL-27
Clutch Pipe and Hose

CLUTCH SYSTEM
6MT model Tightening torque: T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb) T2: 18 Nm (1.8 kgf-m, 13.3 ft-lb) T3: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T1 T1
(A) T3 (B)
(C) (C)
T2
(D) CL-00652
(A) (B) (C) (D)
Clutch pipe Clip Clutch hose Operating cylinder (6MT turbo model)
C: INSPECTION
Check pipes and hoses for cracks, breakage or damage. Check joints for fluid leakage. If any cracks, breakage, damage or leakage is found, repair or replace the defective pipe or hose.
CL-28
Clutch Fluid
CLUTCH SYSTEM
8. Clutch Fluid
A: INSPECTION
1) Park the vehicle on a level surface. 2) Inspect the fluid level using the scale on the outside of the reservoir tank. If the level is below MIN, add fluid to bring it up to MAX, and also inspect for leakage.
(A)
B: REPLACEMENT
CAUTION: Use fresh FMVSS No. 116, DOT3 brake fluid. Cover the bleeder with cloth to prevent brake fluid from being splashed on surrounding parts when loosening the bleeder. Avoid mixing brake fluid of different brands to prevent fluid performance from degrading. Be careful not to allow dirt or dust to enter the reservoir tank. NOTE: During bleeding operation, keep the clutch reservoir tank filled with brake fluid to prevent entry of air. Clutch pedal must be operated very slowly. For convenience and safety, it is advisable to have two people working. The amount of brake fluid required is approximately 70 m2 (2.4 US fl oz, 2.5 Imp fl oz) for total clutch system. 1) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 3) Drain the brake fluid from the reservoir tank. 4) Refill the reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, fresh DOT3 brake fluid 5) If necessary, bleed air from the clutch fluid. <Ref. to CL-30, Clutch Fluid Air Bleeding.>
(B)
M AX MIN
(C)
CL-00183
(A) Reservoir tank (B) MAX. level (C) MIN. level
CL-29
Clutch Fluid Air Bleeding

CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding

A: PROCEDURE
1. 5MT MODEL
NOTE: Bleed air from the oil line with help of a co-worker. 1) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 2) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 3) Fit one end of a vinyl tube into the air bleeder of the operating cylinder, and put the other end into a brake fluid container. NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
(A)
4) Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air together with the fluid. Release the air bleeder for 1 or 2 seconds. Next, with the bleeder closed, slowly release the clutch pedal. CAUTION: Cover the bleeder with cloth to prevent brake fluid from being splashed on surrounding parts when loosening the bleeder. NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
(B)
(A)
CL-00370
(B)
(A) Operating cylinder (B) Vinyl tube

CL-00369
(A) Clutch hose (B) Air bleeder
5) Repeat procedure 4), until there are no more air bubbles in the vinyl tube. 6) Tighten the air bleeder. Tightening torque: T: 7.8 Nm (0.8 kgf-m, 5.8 ft-lb) NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
CL-00372
7) After stepping on the clutch pedal, make sure that there are no leaks evident in the entire clutch system. 8) After bleeding the air from clutch system, ensure that the clutch operates properly.
CL-30
Clutch Fluid Air Bleeding

CLUTCH SYSTEM
9) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, INSTALLATION, Air Intake Chamber.> 10) Install the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-13, INSTALLATION, Intercooler.>
2. 6MT MODEL
NOTE: Bleed air from the oil line with help of a co-worker. 1) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.> 2) Fit one end of a vinyl tube to the air bleeder of the master cylinder, and put the other end into a brake fluid container. 3) Remove the operating cylinder. NOTE: Do not remove the clutch hose.
6) Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air together with the fluid. Release the air bleeder for 1 or 2 seconds. Next, with the bleeder closed, slowly release the clutch pedal. NOTE: When performing this procedure, place the screw portion of the air bleeder higher than the end of operating cylinder.
(A)
(B)
CL-00447
(A) Operating cylinder (B) Vinyl tube
7) Repeat these steps until there are no more air bubbles in the vinyl tube.
CL-00445
4) Hold the piston with a clamp to prevent piston from popping out.
CAUTION: Cover the bleeder with cloth to prevent brake fluid from being splashed on surrounding parts when loosening the bleeder. 8) Tighten the air bleeder. Tightening torque: 7.8 Nm (0.8 kgf-m, 5.8 ft-lb) 9) Install the operating cylinder. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft-lb)
CL-00446
5) Fit one end of a vinyl tube into the air bleeder of the operating cylinder, and put the other end into a brake fluid container.
CL-00445
10) After depressing the clutch pedal, make sure that there are no leaks evident in the entire system. 11) After bleeding air from system, ensure that the clutch operates properly. 12) Install the intercooler. <Ref. to IN(H4DOTC)13, INSTALLATION, Intercooler.>
CL-31
Clutch Pedal
CLUTCH SYSTEM
10.Clutch Pedal
A: REMOVAL
1) Disconnect the ground cable from battery. 2) Remove the steering column. <Ref. to PS-16, REMOVAL, Tilt Steering Column.> 3) Disconnect the connectors of the stop light switch and clutch switch. 4) Remove the snap pins from clevis pins which secure the lever to the push rod and operating rod. 5) Pull out the clevis pins which secures the lever to the push rod and operating rod.
B: INSTALLATION
1) Install in the reverse order of removal. Tightening torque: T: 18 Nm (1.8 kgf-m, 13.3 ft-lb) CAUTION: Always use a new clevis pin. 2) Adjust the clutch pedal after installation. <Ref. to CL-34, ADJUSTMENT, Clutch Pedal.>
C: DISASSEMBLY
1) Remove the clutch switches. 2) Remove the clip, assist spring, rod and bushing.
(D) (D) (A) (D) (E) (C) (B) CL-00292 (C) (C) (D) (B) (E) (C) CL-00573 (D) (A)
(A) (B) (C) (D)
Operating rod Push rod Snap pin Clevis pin
6) Remove the air intake chamber. (Non-turbo model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Chamber.> 7) Remove the intercooler. (Turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.> 8) Remove the nut which secures the clutch master cylinder.
(A) (B) (C) (D) (E)
Clip Assist spring Assist rod Bushing Clevis pin
3) Extract the spring pin and remove the lever.

(A)
(B)
CL-00095
(A) Pin (B) Lever

CL-00093
9) Remove the bolt which secures the brake pedal and clutch pedal, and remove the pedal assembly.
CL-32
Clutch Pedal
CLUTCH SYSTEM
4) Remove the clutch pedal and bushing.

(B)
E: INSPECTION
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbf) to check that the clutch pedal deflection is within the service limit. If it exceeds the service limit, replace with new bushings. Deflection of the clutch pedal: Service limit 4.0 mm (0.157 in) or less
(B)
(A) CL-00574
(A) Clutch pedal (B) Bushing
5) Remove the stopper from the clutch pedal.

(A) (B)
(A)
CL-00098
(A) Clutch pedal (B) Brake pedal

CL-00535
(A) Stopper
6) Remove the clutch pedal pad.
D: ASSEMBLY
1) Temporarily assemble the clutch switch, etc. to pedal bracket. 2) Clean the clutch pedal and brake pedal bushing holes, apply a thin coat of grease, and install the bushings. 3) Align the holes of the pedal bracket, clutch pedal and brake pedal, and install the brake pedal return spring, assist rod, spring and bushing. NOTE: Clean the inside of bushings and apply a thin coat of grease before installing the spacer.
CL-33
Clutch Pedal
CLUTCH SYSTEM
F: ADJUSTMENT
1) Measure the full stroke of the clutch pedal. NOTE: Measure the leading end of the seat cushion and center of the pedal. Align the seat with the seventh notch position from the position at the very front. Specified clutch pedal full stroke A: 5MT non-turbo model and 6MT model: 130 135 mm (5.12 5.31 in) 5MT turbo model: 135 140 mm (5.31 5.51 in)
4) Rotate the push rod to adjust. (1) Make sure that the clutch pedal contacts the clutch switch side when the pedal is released. (2) Make sure that the clutch pedal contacts the clutch pedal bracket stopper when the clutch pedal is at the maximum stroke position.
(A)
(B) (C) (E) (D) (F)
CL-00080
(C) (A) A (B) CL-00078
(A) (B) (C) (D) (E) (F)
Clevis hole Push rod lock nut In the shorter direction In the longer direction Push rod U shaped hardware
A Measured value (A) Clutch pedal (Full stroke condition) (B) Scale (C) Seats
5) Turn the push rod to shorten until a clearance is gained on the clutch switch side.
2) If the full stroke is not within the specified value, loosen the clutch switch lock nut to adjust. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb) 3) Loosen the push rod lock nuts.
(A)
(C) (A)
(B) CL-00538
(A) Clutch switch

(B) (D) (C)
(B) Stopper (C) Clearance
6) Turn the push rod to lengthen until clutch pedal contacts the clutch switch.
CL-00042
(A) (B) (C) (D)
Clevis pin Snap pin Push rod Push rod lock nut
CL-34
Clutch Pedal
CLUTCH SYSTEM
7) Turn further in the direction that will shorten the push rod (arrow direction shown in figure) by 270.
(B)
(A)
13) Push the release lever until the operating cylinder push rod retracts. Make sure that the clutch fluid level in the reservoir tank increases. If the clutch fluid level increases, the hydraulic clutch is properly adjusted;if the fluid level does not increase or the push rod does not retract, replace the master cylinder. <Ref. to CL-25, Master Cylinder.> 5MT model NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
(2)
CL-00101
(A) Accelerator pedal (B) Clevis
(1)
8) Check that the clevis pin moves smoothly by moving it in the left and right directions. 9) Tighten the push rod lock nut. Tightening torque: 10 Nm (1.0 kgf-m, 7.4 ft-lb) 10) Depress and release the clutch pedal two or three times to ensure that the clutch pedal and release fork operate smoothly. If the clutch pedal and release fork do not operate smoothly, bleed air from the clutch hydraulic system. <Ref. to CL-30, Clutch Fluid Air Bleeding.> 11) Measure the clutch pedal full stroke length again to ensure that it is within specifications. If it is not within specifications, repeat adjustment procedures again from the beginning. Specified clutch pedal full stroke: 5MT non-turbo model and 6MT model: 130 135 mm (5.12 5.31 in) 5MT turbo model: 135 140 mm (5.31 5.51 in) 12) Move the clevis pin to left, then to right. The clevis pin should move without resistance even if it is rattling. If resistance is felt, repeat adjustment procedures again from the beginning.
(3) CL-00371
(1) Push rod (2) Release lever (3) Operating cylinder
6MT model
(2)
(3) (1)
CL-00448
(1) Push rod (2) Release lever (3) Operating cylinder
CL-35
Clutch Pedal
CLUTCH SYSTEM
14) Check the fluid level using the scale on the outside of the reservoir tank. If the level is below MIN, fill fluid up to MAX level. Recommended clutch fluid: FMVSS No. 116, fresh DOT3 brake fluid
(A)
(C)
M AX MIN
(B)
CL-00159
CL-36
Clutch Switch
CLUTCH SYSTEM
11.Clutch Switch
A: REMOVAL
1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from clutch switch. 4) Remove the clutch switches.
3) If the clutch pedal stroke is out of specification, adjust the stroke. <Ref. to CL-34, ADJUSTMENT, Clutch Pedal.> 4) Connect the clutch switch connector.
2. CLUTCH SWITCH (CLUTCH START)

1) Fully depress the clutch pedal and hold it. 2) Install the clutch pedal plate and clutch pedal so that the gap between them is 3.1 4.1 mm (0.12 0.16 in), and then tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
(A) (C) (B)
B: INSTALLATION
1. CLUTCH SWITCH (WITH CRUISE CONTROL)
1) Install so that there is a gap of 0 mm (0 in) of the clutch switch and clutch pedal stopper. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
(C)
CL-00104
(A) (B) CL-00536
(A) Plate (B) Clutch pedal (C) 3.1 4.1 mm (0.12 0.16 in)
(A) Clutch switch (B) Stopper (C) 0 mm (0 in)
2) Measure the stroke of the clutch pedal. Clutch pedal standard full stroke: A 5MT non-turbo model and 6MT model 130 135 mm (5.12 5.31 in) 5MT turbo model 135 140 mm (5.31 5.51 in)
3) Connect the clutch switch connector. 4) Make sure that engine does not start with clutch pedal not depressed. 5) Make sure that the engine starts with the clutch pedal fully depressed.
(C) (A) A (B) CL-00078
A Measured value (A) Clutch pedal (Full stroke condition) (B) Scale (C) Seats
CL-37
Clutch Switch
CLUTCH SYSTEM
C: INSPECTION
1) Make sure that engine does not start with clutch pedal not depressed. If the engine starts, adjust the clutch switch and inspect the starter interlock circuit. 2) Make sure that the engine starts with the clutch pedal fully depressed. If the engine does not start, adjust the clutch switch and inspect the starter interlock circuit. 3) Check the clutch switch for continuity. If the resistance is not at the standard value, replace the switch. (1) Disconnect the clutch switch connector. (2) Measure the resistance between terminal 1 and 2 of the switch.
Condition When the clutch pedal is depressed Except when the clutch the pedal is depressed Terminal No. 1 and 2 1 and 2 Specified resistance Less than 1 : 1 M: or more
D: ADJUSTMENT
1) Loosen the lock nut of clutch switch (clutch start).
(A)
(B)
CL-00537
(A) Lock nut (B) Clutch switch (Clutch start)
2) Fully depress the clutch pedal and hold it. 3) Adjust the gap of the clutch pedal plate and the clutch switch to be 3.1 4.1 mm (0.12 0.16 in).
(A) (C) (B)
Clutch switch (Clutch start)
1 2
CL-00104
CL-00102
Clutch switch (Cruise control)
(A) Plate (B) Clutch switch (Clutch start) (C) 3.1 4.1 mm (0.12 0.16 in)
4) Tighten the lock nut.

2 1
CL-00084
CL-38

CLUTCH SYSTEM

A: INSPECTION
1. CLUTCH
Symptom 1. Clutch slippage. It is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms. Engine speeds up when shifting. High-speed driving is not possible; especially rapid acceleration is not possible and vehicle speed does not increase in proportion to the increase in engine speed. Power drops particularly when ascending a slope, and there is a burning smell of the clutch plate. Method of testing: Park the vehicle and fully apply the parking brake. Disengage the clutch and shift the transmission gear into the 1st. Gradually increase the engine speed while gradually allowing the clutch to engage. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not move forward and the engine does not stall. 2. Clutch drags. As a symptom of this trouble, a harsh scratching noise occurs and control becomes difficult when shifting gears. The symptom becomes more apparent when shifting into the 1st gear. However, because most trouble of this sort is due to a defective synchronization mechanism, perform the following tests. Method of testing:<Ref. to CL-40, DIAGNOSTIC DIAGRAM OF CLUTCH DRAG, INSPECTION, General Diagnostic Table.> The problem is caused by insufficient disengagement of the clutch if an abnormal noise occurs during this test. 3. Clutch chatters. Clutch chattering is an unpleasant vibration to the whole vehicle when the vehicle is just started with clutch partially engaged. Possible cause (a) Oil on the clutch face (b) Worn clutch face (c) Deteriorated diaphragm spring (d) Warped pressure plate or flywheel (e) Defective release bearing holder Corrective action Replace. Replace. Replace. Repair or replace. Repair or replace.
(a) Worn or rusty clutch disc hub spline (b) Excessive deflection of clutch disc face (c) Crankshaft pilot needle bearing sticking (d) Cracked clutch disc face (e) Stuck clutch disc (smeared by oil or water)
Replace the clutch disc. Repair or replace. Replace. Replace. Replace.
4. Noisy clutch Examine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged.
(a) Adhesion of oil on the clutch face (b) Weak or broken damper spring (c) Poor contact of the disc surface or excessively worn disc (d) Warped pressure plate or flywheel (e) Loose disc rivets (f) Loose engine mounting (g) Improper adjustment of the pitching stopper (a) Broken, worn or insufficiently lubricated release bearing (b) Insufficient lubrication of the pilot bearing
Replace the clutch disc. Replace the clutch disc. Replace the faulty clutch disc. Repair or replace. Replace the clutch disc. Retighten or replace mounting. Adjust. Replace the release bearing. Replace the pilot bearing.
(c) Loose clutch disc hub Replace the clutch disc. (d) Loose damper spring retainer Replace the clutch disc. (e) Deteriorated or broken Replace the clutch disc. damper spring
CL-39

CLUTCH SYSTEM
Symptom 5. Clutch grabs suddenly. When starting the vehicle with the clutch partially engaged, the clutch engages suddenly and the vehicle jumps instead of making a smooth start. Possible cause (a) Grease or oil on facing (b) Deteriorated cushioning spring (c) Worn or rusted spline of clutch disc or main shaft (d) Deteriorated or broken damper spring (e) Loose engine mounting (f) Deteriorated diaphragm spring Corrective action Replace the clutch disc. Replace the clutch disc. Take off rust, apply grease or replace clutch disc or main shaft. Replace the clutch disc. Retighten or replace mounting. Replace.
2. CLUTCH PEDAL
Symptom Corrective action Insufficient pedal play Adjust the free play of the pedal. Insufficient clutch pedal free play Adjust the free play of the pedal. Excessively worn and damaged pedal shaft and/or bushing Replace the bushing or shaft with a new part.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

1 Step CHECK GEAR NOISE. 1) Start the engine. 2) Disengage the clutch and shift quickly from neutral to reverse in idling condition. CHECK GEAR NOISE. Disengage the clutch at idle and shift from neutral to reverse within 0.5 1.0 seconds. Check Is there any abnormal noise from the transmission gear? Yes Go to step 2. No Clutch is normal.
Is there any abnormal noise from the transmission gear?
Go to step 3.
CHECK GEAR NOISE. Is there any abnormal noise 1) Disengage the clutch at idle and shift from from the transmission gear? neutral to reverse within 0.5 1.0 seconds. 2) With the clutch disengaged, shift from neutral to reverse, reverse to neutral several times.
Inadequate clutch disengage. Inspect the clutch disc, clutch cover, clutch release, and clutch pedal free play.
Defective transmission or excessive clutch drag torque. Inspect pilot bearing, clutch disc, transmission and clutch disc hub spline. Clutch and flywheel seizure. Inspect the clutch disc and the spline of the clutch disc hub.
CL-40
General Description
FRONT SUSPENSION
A: SPECIFICATION
Model Wheel arch height mm (in) (Tolerance: +12 mm 24 mm (+0.47 in 0.94 in )) Camber (Tolerance: r045c Differences between RH and LH: 45c or less) Caster (Referential Value) Inner wheel Steering angle (Tolerance: r1.5) Outer wheel Toe-in mm (in) Kingpin angle (Referential Value) Wheel arch height mm (in) (Tolerance: +12 mm 24 mm (+0.47 in 0.94 in )) Camber (Tolerance: r045c Differences between RH and LH: 45c or less) Toe-in mm (in) Thrust angle (Tolerance: r030c) 2.5 i Sedan 2.5 GT spec.B, 2.5 GT spec.B, 3.0 R 3.0 R-LTD 381 (15.0) 015c 555c 37.6 33.0 33.8 30.2 540c 37.6 33.0 Wagon 2.5 i 2.5 GT OUTBACK 439 (17.3) 040c 455c
Front
0r3 (0r0.12) Toe angle (sum of both wheels): 0r015c 1345c 1205c 365 (14.4) 040c
*2
375 (14.8) 030c
438 (17.2) 010c

*1
Rear
*1:
OUTBACK model 3 0 mm (0.12 0 in) Toe angle (sum of both wheels): 015c 0 *2: Except for OUTBACK model 0r3 mm (0r0.12 in) Toe angle (sum of both wheels): 0r015c
NOTE: Front and rear toe-in and front camber can be adjusted. Adjust if the toe-in or camber tolerance exceeds specifications. Other items indicated in the specifications table cannot be adjusted. If other items exceed specifications, check the suspension parts and connections for deformation, and replace with new parts as required.
(1)
A FS-00269
(1) Front A B = Positive: Toe-in, Negative: Toe-out D = Individual toe angles
FS-2
General Description
FRONT SUSPENSION
B: COMPONENT
T1 (16) T7 (26) (17) (18) (15) (26) (19) T8 T10 (6) (5) T11 T10 (8) (1) T6 (2)
(20) (21) T8 (22) (13) (12) T5 (26) (23) T5 (26) T8
(3) (7) (4) (25) T4 (27)
T9 (26) T12
(6)
(3) (24) (11) (10) T2 T8 (26) T13 FS-00256 (9) (14) T8 (26) T2 (7) (28) (25) T3 (27)
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Front crossmember Housing Ball joint Front arm (steel type) Support plate Rear bushing Front bushing Stud bolt Stabilizer link Bracket Bushing Stabilizer Crossmember support plate (Large type) Crossmember support plate (Small type)
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Jack-up plate Dust seal Strut mount Spacer Upper spring seat Dust cover Helper Coil spring Damper strut Adjusting bolt Castle nut Self-locking nut Cotter pin Front arm (aluminium type)
Tightening torque:Nm (kgf-m, ft-lb) T1: 20 (2.0, 14.5) T2: 25 (2.5, 18.1) T3: 30 (3.1, 22) T4: 39 (4.0, 28.8) T5: 45 (4.6, 33.2) T6: 50 (5.1, 36.9) T7: 55 (5.6, 41) T8: 60 (6.1, 44.3) T9: 88 (9.0, 64.9) T10: 95 (9.7, 70.1) T11: 110 (11.2, 81.1) T12: 150 (15.3, 110.6) T13: 155 (15.8, 114.3)
FS-3
General Description
FRONT SUSPENSION
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 927680000 DESCRIPTION INSTALLER & REMOVER SET REMARKS Used for replacing front arm front bushing.
ST-927680000
20299AG000
REMOVER
Used for replacing front arm rear bushing. Used together with BASE (20999AG010).
ST20299AG000
20299AG010
BASE
Used for replacing front arm rear bushing. Used together with REMOVER (20999AG000).
ST20299AG010
FS-4
General Description
FRONT SUSPENSION
ILLUSTRATION TOOL NUMBER 20299AG020 DESCRIPTION STUD BOLT SOCKET REMARKS Used for removing and installing the stud bolt for front arm installing portion.
ST20299AG020
20399AG000
STRUT MOUNT SOCKET
Used for disassembling and assembling strut mount.
ST20399AG000
2. GENERAL TOOL
TOOL NAME Alignment gauge Alignment gauge adapter Turning radius gauge Toe-in gauge Dial gauge Coil spring compressor REMARKS Used for measuring wheel alignment. Used for measuring wheel alignment. Used for measuring wheel alignment. Used for toe-in measurement. Used for damper strut measurement. Used for strut assembly/disassembly.
FS-5
Wheel Alignment
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check the following items before performing the wheel alignment measurement. Check items before measuring wheel alignment: Tire inflation pressure Uneven wear of RH and LH tires, or difference of sizes Tire runout Excessive play and wear of ball joint Excessive play and wear of tie-rod end Excessive play of wheel bearing Right and left wheel base imbalance Deformation and excessive play of steering link Deformation and excessive play of suspension parts Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure.
Wheel arch height (front and rear wheels) <Ref. to FS-7, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.> p Camber (front and rear wheels) <Ref. to FS-8, CAMBER, INSPECTION, Wheel Alignment.> p Caster (front wheel) <Ref. to FS-10, CASTER, INSPECTION, Wheel Alignment.> p Steering angle <Ref. to FS-10, STEERING ANGLE, INSPECTION, Wheel Alignment.> p Front wheel toe-in <Ref. to FS-10, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.> p Rear wheel toe-in <Ref. to FS-11, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.> p Thrust angle <Ref. to FS-13, THRUST ANGLE, INSPECTION, Wheel Alignment.>
FS-6
Wheel Alignment
FRONT SUSPENSION
1. WHEEL ARCH HEIGHT

1) Park the vehicle on a level surface. 2) Empty the vehicle so that it is at curb weight. (Empty the luggage compartment, load the spare tire, jack and service tools, and fill up the fuel tank.) 3) Set the steering wheel in a straight-ahead position, and stabilize the suspensions by moving the vehicle in a straight line for 5 m (16 ft) or more. 4) Suspend a thread from the wheel arch (point A in the figure below) and affix at a position directly above the center of wheel. 5) Measure the distance between the point A and the center of wheel.
(2)
(3)
A (1) (1)
(6)
(7)
(4)
(5)
(1)
(8) FS-00125
(1) (2) (3)
Wheel arch height Front fender Rear quarter
(4) (5) (6)
Front wheel arch height Rear wheel arch height Flange bend line
(7) (8)
Point of measurement End of spindle
Model Front Rear
Wheel arch height specification mm (in) (Tolerance: +12 mm 24 mm (+0.47 in 0.94 in)) Sedan Wagon All models Except for OUTBACK 381 (15.0) 381 (15.0) 365 (14.4) 375 (14.8)
OUTBACK 439 (17.3) 438 (17.2)
FS-7
Wheel Alignment
FRONT SUSPENSION
2. CAMBER
INSPECTION 1) Place the front wheel on the turning radius gauge. Make sure the ground contact surfaces of the front and rear wheels are at the same height. 2) Set the adapter into the center of wheel, and then set the wheel alignment gauge.
(3)
FRONT CAMBER ADJUSTMENT 1) When adjusting the camber, adjust it to the following value.
Model Except for OUTBACK OUTBACK Camber (Difference between RH and LH 45c or less) 015cr030c 040cr030c
2) Loosen the two self-locking nuts located at the front lower section of the strut. NOTE: When the adjusting bolt needs to be loosened or tightened, hold its head with a wrench and turn the self-locking nut. 3) Turn the camber adjusting bolt so that the camber is set at specification.
FS-00213
(1)
(2)
(1) Alignment gauge (2) Turning radius gauge (3) Adapter
NOTE: Moving the adjusting bolt by one scale changes the camber by approximately 015c.
(1)
3) Measure the camber angle in accordance with the operation manual for wheel alignment gauge.
Model Except for OUTBACK OUTBACK Camber (Difference between RH and LH 45c or less) 015cr045c 040cr045c
(6)
(4)
(5)
(7)
(2) (3) FS-00008
(1) (2) (3) (4) (5) (6) (7)
Strut Adjusting bolt Housing Outer Inner Camber is increased. Camber is decreased.
FS-8
Wheel Alignment
FRONT SUSPENSION
To increase camber: Rotate the left side counterclockwise. Rotate the right side clockwise.
FS-00009
FS-00010
To decrease camber: Rotate the left side clockwise. Rotate the right side counterclockwise.
FS-00010
FS-00009
4) Tighten two new self-locking nuts. Tightening torque: 155 Nm (15.8 kgf-m, 114.3 ft-lb)
FS-9
Wheel Alignment
FRONT SUSPENSION
3. CASTER
INSPECTION 1) Place the front wheel on the turning radius gauge. Make sure the ground contact surfaces of the front and rear wheels are at the same height. 2) Set the adapter into the center of wheel, and then set the wheel alignment gauge.
(3)
ADJUSTMENT 1) Turn the tie-rod to adjust the steering angle of both inner and outer wheels. 2) Check the toe-in. NOTE: Correct the boot if it is twisted.
(1) (1)
(2)
FS-00014 FS-00213
(1) Lock nut (1) Alignment gauge (2) Turning radius gauge (3) Adapter
5. FRONT WHEEL TOE-IN

INSPECTION Toe-in: 0r3 mm (0r0.12 in) 1) Set the toe-in gauge in the position at wheel axis center height behind the right and left front tires. 2) Place a mark at the center of both left and right tires, and measure distance A between the marks. 3) Move the vehicle forward to rotate the tires 180. NOTE: Be sure to rotate the tires in the forward direction. 4) Measure the distance B between the left and right marks. Find toe-in using the following equation: A B = Toe-in
3) Measure the caster angle in accordance with the operation manual for wheel alignment gauge.
Model Sedan Wagon OUTBACK Caster (Reference) 555c 540c 455c
4. STEERING ANGLE
INSPECTION 1) Place the vehicle on turning radius gauge. 2) While depressing the brake pedal, turn the steering wheel fully to the left and right. With the steering wheel held at each fully turned position, measure both the inner and outer wheel steering angles.
Model Other than below 2.5 GT spec.B, 3.0 R-LTD Inner wheel 37.6r1.5 33.8r1.5 Outer wheel 33.0r1.5 30.2r1.5
FS-00015
FS-10
Wheel Alignment
FRONT SUSPENSION
ADJUSTMENT When adjusting the toe-in, adjust it to the following value. Toe-in: 0r2 mm (0r0.08 in) 1) Check that the left and right wheel steering angles are within specification. 2) Loosen the left and right side steering tie-rod lock nuts. 3) Turn the left and right tie-rods by equal amounts until the toe-in is at the specification. Both the left and right tie-rods are right-hand threaded. To increase toe-in, turn both tie-rods clockwise by equal amount (viewing from the inside of vehicle).
6. REAR WHEEL TOE-IN

INSPECTION Toe-in: OUTBACK model 3 0 mm (0.12 0 in) Except for OUTBACK model 0r3 mm (0r0.12 in) Refer to FRONT WHEEL TOE-IN for rear toe-in inspection procedures. <Ref. to FS-10, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.> ADJUSTMENT When adjusting, adjust it to the following value. Toe-in: OUTBACK model 3 0 mm (0.12 0 in) Except for OUTBACK model 0r2 mm (0r0.08 in) 1) Loosen the self-locking nut on the inner side of rear link. NOTE: When loosening or tightening the adjusting bolt, hold the bolt head and turn the self-locking nut.
(1)
FS-00014
(1) Lock nut

(1)
4) Tighten the tie-rod lock nut. Tightening torque: 85 Nm (8.7 kgf-m, 62.7 ft-lb) NOTE: Check and correct the tie-rod boot if twisted.
FS-00103 (2)
(1) Adjusting bolt (2) Rear link
FS-11
Wheel Alignment
FRONT SUSPENSION
2) Turn the adjusting bolt until toe-in is within the specification. NOTE: When the left and right wheels are adjusted for toe-in at the same time, the movement of one scale graduation changes toe-in by approx. 0.6 mm (0.02 in).
To increase toe-in: Rotate the left side clockwise. Rotate the right side counterclockwise.
FS-00018
FS-00019
To decrease toe-in: Rotate the left side counterclockwise. Rotate the right side clockwise.
FS-00019
FS-00018
3) Attach and tighten a new self-locking nut. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb)
FS-12
Wheel Alignment
FRONT SUSPENSION
7. THRUST ANGLE
INSPECTION 1) Park the vehicle on a level surface. 2) Move the vehicle 3 to 4 meters (10 to 13 feet) straight forward. 3) Draw the center of loci for both the front and rear axles. 4) Measure distance L between the center lines of the axle loci. Thrust angle 0r30c Less than 30c when L is 23 mm (0.9 in) or less.
ADJUSTMENT When adjusting, adjust it to the following value. Thrust angle 0r20c Less than 20c when L is 15 mm (0.6 in) or less. 1) Make thrust angle adjustments by turning the toe-in adjusting bolts of the rear suspension equally in the same direction. 2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toeout direction, in order to make the thrust angle adjustment. 3) When the left and right adjusting bolts are turned by one graduation, the thrust angle will change approx. 17c (L is approx. 13 mm (0.51 in)). NOTE: Thrust angle is a mean value of left and right wheel toe angles in relation to the vehicle body center line. Vehicle is driven straight in the thrust angle direction while slanting in the oblique direction depending on the degree of the mean thrust angle.
(1) (3)
(1)
(2)
(2)
FS-00024 L FS-00022
(1) Center line of loci (front axle) (2) Center line of loci (rear axle)
(1) Front (2) Thrust angle (3) Body center line
Thrust angle: r = (D E)/2 D: Rear RH wheel toe-in angle E: Rear LH wheel toe-in angle Substitute only the positive toe-in values from each wheel into D and E in the equation.
(1) (2)
FS-00976
(1) Front (2) Body center line
FS-13
Front Crossmember Support Plate

FRONT SUSPENSION
3. Front Crossmember Support Plate

A: REMOVAL
1) Lift up the vehicle 2) Remove the front under cover. <Ref. to EI-26, REMOVAL, Front Under Cover.> 3) Remove the bolt and remove front crossmember support plate. Large type
FS-00104
Small type
(2) (1)
(1) FS-00105
(1) Crossmember support plate (2) Jack-up plate
B: INSTALLATION
Install in the reverse order of removal. NOTE: Tighten the small type crossmember support plate together with stabilizer bracket. After installing the stabilizer bracket to the crossmember, tighten the crossmember support plate together. Tightening torque: Crossmember support plate: 60 Nm (6.1 kgf-m, 44.3 ft-lb) Crossmember support plate (Tightened together with the stabilizer bracket): 25 Nm (2.5 kgf-m, 18.1 ft-lb) Jack-up plate: 60 Nm (6.1 kgf-m, 44.3 ft-lb)
FS-14
Front Stabilizer
FRONT SUSPENSION
4. Front Stabilizer
A: REMOVAL
1) Lift up the vehicle, and then remove the front wheels. 2) Remove the front under cover. <Ref. to EI-26, REMOVAL, Front Under Cover.> 3) Remove the front crossmember support plate. <Ref. to FS-14, REMOVAL, Front Crossmember Support Plate.> 4) Remove the stabilizer link.
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Be sure to use a new self-locking nut. Ensure the stabilizer bushing and stabilizer have the same identification colors. Install the stabilizer bushing (front crossmember side) while aligning it with the paint mark on stabilizer. The stabilizer bracket has a set orientation. Install it with the arrow mark facing the upper side of the vehicle.
(1)
FS-00262
5) Remove the stabilizer bracket.

(1) Front side of vehicle
FS-00229
Tightening torque: Stabilizer link: 45 Nm (4.6 kgf-m, 33.2 ft-lb) Stabilizer bracket: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
FS-00228
1) Check the bushing for abnormal fatigue or damage. 2) Check the stabilizer link for damage.
FS-15
Front Ball Joint

FRONT SUSPENSION
5. Front Ball Joint

A: REMOVAL
1) Lift up the vehicle, and remove the front wheels. 2) Remove the both sides of stabilizer bracket.
B: INSTALLATION
1) Insert the ball joint into housing. Tightening torque (Bolt): 50 Nm (5.1 kgf-m, 36.9 ft-lb) CAUTION: Do not apply grease to the tapered portion of ball stud. 2) Install the ball joint into front arm. Tightening torque (castle nut): Front arm (aluminium type): 30 Nm (3.1 kgf-m, 22 ft-lb) Front arm (steel type): 39 Nm (4.0 kgf-m, 28.8 ft-lb) 3) Retighten the castle nut further up to 60 until the hole in the ball stud is aligned with a slot in castle nut. Then, insert a new cotter pin and bend it around the castle nut. 4) Install the stabilizer bracket. NOTE: The stabilizer bracket has a set orientation. Install it with the arrow mark facing the upper side of the vehicle.
(1)
FS-00228
3) Pull out the pin from ball stud, remove the castle nut, and extract the ball stud from front arm. 4) Remove the bolt installing ball joint to housing.
FS-00115
5) Extract the ball joint from housing.
FS-00229
(1) Front side of vehicle
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 5) Install the front wheels.
FS-16
Front Ball Joint

FRONT SUSPENSION
C: INSPECTION
1) Measure the play of the ball joint using the following procedures. Replace with a new part if the play exceeds specification. (1) With 686 N (70 kgf, 154 lb) loaded in direction shown in the figure, measure the length 21.
FS-00035
(2) With 686 N (70 kgf, 154 lb) loaded in direction shown in the figure, measure the length 22.
FS-00036
(3) Determine free play using the following formula. S = 22 21 (4) Replace with a new part if the play exceeds specification. Front ball joint Specification for replacement S: Less than 0.3 mm (0.012 in) 2) If the play is within specification, visually check the dust cover. 3) Remove the ball joint and cover, and check for wear, damage or cracks. If any damage is found, replace the corresponding part. 4) If the dust cover is damaged, replace with a new ball joint.
FS-17
Front Arm
FRONT SUSPENSION
6. Front Arm
A: REMOVAL
1) Lift up the vehicle, and then remove the front wheels. 2) Remove the front crossmember support plate. <Ref. to FS-14, REMOVAL, Front Crossmember Support Plate.> 3) Remove the front stabilizer. <Ref. to FS-15, REMOVAL, Front Stabilizer.> 4) Remove the ball joint of front arm.
8) To remove the stud bolt, use the ST. ST 20299AG020 STUD BOLT SOCKET CAUTION: Do not remove the stud bolt unnecessarily. Always replace the parts with new parts when removed.
(1) (2)
ST FS-00109
(1) Vehicle body (2) Stud bolt

FS-00106
B: INSTALLATION
1) Using the ST, install the stud bolt. ST 20299AG020 STUD BOLT SOCKET Tightening torque: 110 Nm (11.2 kgf-m, 81.1 ft-lb) 2) Using new bolts and self-locking nuts, temporarily tighten the front arm to crossmember. 3) Secure the front arm to body, and then install the support plate with new bolts and self-locking nuts. Tightening torque: Support plate to Front arm: 88 Nm (9.0 kgf-m, 64.9 ft-lb) Support plate to Body: 150 Nm (15.3 kgf-m, 110.6 ft-lb) 4) Install the ball joint into housing. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 5) Install the stabilizer. <Ref. to FS-15, INSTALLATION, Front Stabilizer.> 6) Lower the vehicle from lift, and tighten the bolt which secures the front arm to crossmember with wheels in full contact with the ground and the vehicle at curb weight.
5) Remove the nut securing the front arm to crossmember. (Do not remove the bolt.)
FS-00107
6) Remove the front arm support plate.
FS-00108
7) Remove the bolt securing front arm to crossmember and pull the front arm out of the crossmember.
Tightening torque: 95 Nm (9.7 kgf-m, 70.1 ft-lb) 7) Inspect the wheel alignment and adjust if necessary.
FS-18
Front Arm
FRONT SUSPENSION
C: DISASSEMBLY
1. FRONT BUSHING
Using the ST and a press, remove the front bushing. ST 927680000 INSTALLER & REMOVER SET
D: ASSEMBLY
1. FRONT BUSHING
2. REAR BUSHING
1) Install the rear bushing with its longer inner cylinder facing upward and the shorter facing downward and protruding part rearward as shown in the figure.
(1) (5) (3)
ST
FS-00110
2. REAR BUSHING
1) Put an alignment mark on the front arm based on the center of rear bushing recess portion. CAUTION: Always put an alignment mark for aligning the position on bushing installation.
(1) (2) (3) (4) (5) Front arm Bushing inner cylinder Longer Shorter Protrusion portion
(4) (2) FS-00113
(1)
2) Align the center of rear bushing recess portion with the aligning mark on the front arm.
(2) (1) (1) FS-00136
(1) Put an alignment mark. (2) Recess section
(2)
2) Using the ST and a press, remove the rear bushing. ST1 20299AG000 REMOVER ST2 20299AG010 BASE
(1) ST1 (2)
(1) FS-00136
(1) Alignment mark (2) Recess section
ST2 (3) FS-00126
(1) Press (2) Front arm (3) Rear bushing
FS-19
Front Arm
FRONT SUSPENSION
3) Using the ST and a press, install the rear bushing. ST1 20299AG000 REMOVER ST2 20299AG010 BASE
(1) ST1
(2)
(3)
ST2 FS-00127
(1) Press (2) Front arm (3) Rear bushing
E: INSPECTION
1) Check the front arm for damage or cracks, and correct or replace if defective. 2) Check the bushing for abnormal fatigue or damage.
FS-20
Front Strut
FRONT SUSPENSION
7. Front Strut
A: REMOVAL
1) Lift up the vehicle, and then remove the front wheels. 2) Place an alignment mark on the camber adjusting bolt and strut. 3) Remove the bolt securing the brake hose from the strut.
6) Remove the three nuts securing strut mount to body.
FS-00037
4) Remove the bolt securing the ABS wheel speed sensor harness.
FS-00039
B: INSTALLATION
1) Install the strut mount at the upper side of strut to body, and tighten it with new self-locking nuts. Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft-lb) 2) Align alignment marks on the camber adjusting bolt and strut. Using new self-locking nuts, install the strut to the housing. NOTE: While holding the head of adjusting bolt, tighten the self-locking nut. Tightening torque: 155 Nm (15.8 kgf-m, 114.3 ft-lb) 3) Secure the ABS wheel speed sensor harness to the strut. Tightening torque: 33 Nm (3.4 kgf-m, 24.3 ft-lb) 4) Install the bolts which secure the brake hose to the strut. Tightening torque: 33 Nm (3.4 kgf-m, 24.3 ft-lb) 5) Install the front wheels. 6) Inspect the wheel alignment and adjust if necessary.
FS-00038
5) Remove the two bolts securing the housing to the strut. NOTE: While holding the head of the adjusting bolt, loosen the self-locking nut.
FS-21
Front Strut
FRONT SUSPENSION
C: DISASSEMBLY
1) Using a coil spring compressor, compress the coil spring.
D: ASSEMBLY
1) Before installing the coil spring, strut mount, etc. on strut, check for the presence of air in the dampening force generating mechanism of the strut since air prevents proper dampening force production. 2) Checking for presence of air (1) Place the strut vertically with the piston rod facing up. (2) Move the piston rod to the center of its entire stroke. (3) While holding the piston rod end with fingers, move the rod up and down. (4) If the piston rod moves 10 mm (0.39 in) or more in the former step, purge air from the strut. 3) Air purging procedure (1) Place the strut vertically with the piston rod facing up. (2) Fully extend the piston rod. (3) With the piston rod fully extended, place the piston rod side down. The strut must stand vertically. (4) Fully retract the piston rod. (5) Repeat 3 or 4 times from the step (1). NOTE: After purging air from the strut, be sure to place the strut with the piston rod facing up. If the strut is laid down for any reason, check for the entry of air in accordance with Checking for presence of air 4) Using a coil spring compressor, compress the coil spring. NOTE: Make sure that the vertical install direction of the coil spring is as shown in the figure.
(1)
FS-00040
2) Using the ST, remove the self-locking nut. ST 20399AG000 STRUT MOUNT SOCKET
ST
FS-00041
3) Remove the strut mount, spacer and upper spring seat from strut. 4) Gradually decrease the compression force of compressor, and remove the coil spring. 5) Remove the dust cover and helper spring.
(2)
(3)
FS-00231
(1) Diameter is small (Upper part) (2) Identification paint (3) Diameter is large (Bottom part)
FS-22
Front Strut
FRONT SUSPENSION
5) Set the coil spring correctly so that its end face seats well in the spring seat as shown in the figure.
E: INSPECTION
Check the removed part for wear, damage and cracks, and then repair or replace it if defective.
1. STRUT
1) Check for oil leaks. 2) Move the piston rod up and down to check that it operates smoothly without any hitch. 3) Piston rod play Measure the play as follows: Fix the outer shell in place and fully extend the rod. Set a dial gauge at the end of rod L [10 mm (0.39 in)], and then read the dial gauge indication P1 while applying a force of W [20 N (2 kgf, 4 lb)] to the threaded portion. Apply a force of 20 N (2 kgf, 4 lb) from the opposite direction of W, and then read the dial gauge indication P2.
(1) FS-00043
(1) Coil spring end face
6) Install the helper and dust cover to the piston rod. 7) Pull the piston rod fully upward, and install the spring seat. NOTE: Position the upper spring seat as shown in the figure.
FS-00046
Play limit (P1 + P2): 0.8 mm (0.031 in) If the play exceeds limit, replace the strut.
(1) FS-00128
2. STRUT MOUNT
Check the rubber part for deformation, cracks or deterioration, and then replace it with a new part if defective.
(1) Outside of body
8) Install spacer and the strut mount to piston rod, and tighten a new self-locking nut temporarily. 9) Using a hexagon wrench to prevent strut rod from turning, tighten the new self-locking nut with ST. ST 20399AG000 STRUT MOUNT SOCKET Tightening torque: 55 Nm (5.6 kgf-m, 41 ft-lb)
ST
3. DUST COVER
If major cracks or damage are found, replace it with a new part.
4. COIL SPRING
If a permanent strain is found, replaced it with a new part.
5. HELPER
If major cracks or damage are found, replace it with a new part.
FS-00041
10) Loosen the coil spring compressor carefully.
FS-23
Front Strut
FRONT SUSPENSION
F: DISPOSAL
1. EXCEPT FOR BILSTEIN STRUT
CAUTION: Before handling struts, be sure to wear goggles to protect eyes from gas, oil and cutting powder. Do not disassemble the strut damper or throw into flames. When discarding gas filled struts, drill holes in them to purge the gas. 1) Place the strut on a level surface with the piston rod fully expanded. 2) Using a 2 3 mm (0.08 0.12 in) dia. drill, make holes in areas shown in the figure.
(1) FS-00047
(1) 40 mm (1.57 in)
2. BILSTEIN STRUT
CAUTION: Before handling struts filled with gas, be sure to wear goggles to protect eyes from gas, oil and metal shavings. Do not disassemble the strut damper or throw into flames. When discarding gas filled struts, drill holes in them to purge the gas. 1) Place the gas-filled strut on a level surface with the damping tube fully extended. 2) Using a 2 3 mm (0.08 0.12 in) dia. drill, make the holes at (1) first, and then (2).
(3) (1) (2)
(4) FS-00096
(1) (2) (3) (4)
20 mm (0.78 in) 10 mm (0.39 in) Strut Damping tube
FS-24
Front Crossmember
FRONT SUSPENSION
8. Front Crossmember
A: REMOVAL
1) Lift up the vehicle, and then remove the front wheels. 2) Remove the front exhaust pipe. 3) Remove the front crossmember support plate. <Ref. to FS-14, REMOVAL, Front Crossmember Support Plate.> 4) Remove the front stabilizer. <Ref. to FS-15, REMOVAL, Front Stabilizer.> 5) Disconnect the tie-rod end from housing. 6) Remove the front arm. <Ref. to FS-18, REMOVAL, Front Arm.> 7) Remove the nuts attaching the engine mount cushion rubber to crossmember.
B: INSTALLATION
1) Install in the reverse order of removal. CAUTION: Use a new bolt and self-locking nut. For parts which are not reusable, refer to COMPONENT. <Ref. to FS-3, COMPONENT, General Description.> Always tighten the stabilizer bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. Tightening torque: Crossmember to body: 95 Nm (9.7 kgf-m, 70.1 ft-lb) Engine mounting to Crossmember: 75 Nm (7.6 kgf-m, 55.3 ft-lb) Front arm to Crossmember: 95 Nm (9.7 kgf-m, 70.1 ft-lb) Front arm to Support plate: 88 Nm (9.0 kgf-m, 64.9 ft-lb) Support plate to Body: 150 Nm (15.3 kgf-m, 110.6 ft-lb) Tie-rod end to Housing: 27.0 Nm (2.75 kgf-m, 19.9 ft-lb) After tightening to the specified torque, tighten the castle nut further but within 60 until the hole in the ball stud is aligned with a slot in castle nut Universal joint: 24 Nm (2.4 kgf-m, 17.7 ft-lb) Stabilizer bracket: 25 Nm (2.5 kgf-m, 18.1 ft-lb) Stabilizer link: 45 Nm (4.6 kgf-m, 33.2 ft-lb) Power steering hose to Steering gearbox: 15 Nm (1.5 kgf-m, 11 ft-lb) 2) Purge air from the power steering system. 3) Inspect the wheel alignment and adjust if necessary.
FS-00118
8) Remove the steering universal joint. 9) Disconnect the power steering hose from steering gearbox. 10) Lift the engine approx. 10 mm (0.39 in) using a chain block. 11) Support the crossmember with a jack, remove the bolts securing crossmember to body, and then gradually lower the crossmember with steering gearbox as a unit. CAUTION: When removing the crossmember downward, be careful that the tie-rod end does not interfere with drive shaft boot.
C: INSPECTION
Check the crossmember for wear, damage or cracks, and then repair or replace if faulty.
FS-00119
FS-25

FRONT SUSPENSION
9. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause (1) Permanent distortion or damage of the coil spring (2) Rough operation of strut or shock absorber (3) Improper installation of strut or shock absorber (4) Installation of the wrong coil spring Corrective action Replace. Replace. Replace with appropriate parts. Replace with appropriate parts.
2. POOR RIDE COMFORT

1) Large rebound shock 2) Rocking of the vehicle continues too long after running over bump and hump. 3) Excessive shock in bumping
Possible cause (1) Damaged coil spring (2) Overinflation of tires (3) Improper wheel arch height (4) Fault in operation of strut or shock absorber (5) Damage or deformation of strut mount or shock absorber mount (6) Unsuitable length (maximum or minimum) of strut or shock absorber (7) Deformation or loss of bushing (8) Deformation or damage of helper in strut assembly or shock absorber (9) Oil leakage from the strut or shock absorber Corrective action Replace. Adjust. Adjust or replace the coil springs with new parts. Replace. Replace. Replace with appropriate parts. Replace. Replace. Replace.
3. NOISE
Possible cause (1) Wear or damage of strut or shock absorber component parts (2) Loosening of the suspension link installing bolt (3) Deformation or loss of bushing (4) Unsuitable length (maximum or minimum) of strut or shock absorber (5) Damaged coil spring (6) Wear or damage of the ball joint (7) Deformation of the stabilizer clamp Corrective action Replace. Tighten to the specified torque. Replace. Replace with appropriate parts. Replace. Replace. Replace.
FS-26
General Description
REAR SUSPENSION
A: SPECIFICATION
Refer to FS section for rear suspension specifications. <Ref. to FS-2, SPECIFICATION, General Description.> NOTE: Front and rear toe-in and front camber can be adjusted. Adjust if the toe-in or camber tolerance exceeds specifications. Other items indicated in the specifications table cannot be adjusted. If other items exceed specifications, check the suspension parts and connections for deformation, and replace with new parts as required.
(1)
A FS-00269
(1) Front A B = Positive: Toe-in, Negative: Toe-out D = Individual toe angles
RS-2
General Description
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
(2) T1 (1)
(22) (20) (3)
T7 (2)
T12 (23)
(22) (4)
(5)
(6) T12 (9) (10) (2) T5 (2) T5 (19) (17) (16) (14) (18) T10 (2) T2 (15) T8 (2) (2) (13) T9 (2) (7) T5 (2) (11) (2) (8) T4
T3
(12)
T10
(21) (24) T11 T12 T6 RS-00238
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Shock absorber Self-locking nut Stabilizer Stabilizer bushing Bracket Stabilizer link Rear link Adjusting bolt Rear link bushing Adjusting washer Rear arm Rear arm rear bushing Rear arm front bushing
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Rear arm bracket Helper Upper link Upper link bushing (inner side) Upper link bushing (outer side) Front link Rear sub frame Sub frame support arm Sub frame lower stopper Spacer Stabilizer link bracket (model with aluminum rear arm)
Tightening torque:Nm (kgf-m, ft-lb) T1: 30 (3.1, 22.4) T2: T3: T4: T5: T6: T7: T8: T9: T10: T11: T12: 32 (3.3, 24) 38 (3.9, 28) 44 (4.5, 32.5) 57 (5.8, 42) 60 (6.1, 44) 62 (6.3, 46) 65 (6.6, 48) 120 (12.2, 89) 125 (12.7, 92) 150 (15.3, 111) 175 (17.8, 129)
RS-3
General Description
REAR SUSPENSION
2. SHOCK ABSORBER
T1 (6) (4) (6)
T2
(1)
(2)
(3) (5)
T3
(6) RS-00037
(1) (2) (3)
Mount Upper rubber sheet Dust cover
(4) (5) (6)
Coil spring Shock absorber Self-locking nut
Tightening torque:Nm (kgf-m, ft-lb) T1: 30 (3.1, 22.4) T2: 35 (3.6, 26) T3: 62 (6.3, 46)
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Before disposing of shock absorbers, be sure to bleed the gas out completely. Also, do not expose to flames or fire. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points.
RS-4
General Description
REAR SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 20099AE000 DESCRIPTION INSTALLER & REMOVER REMARKS Used for replacing the rear link bushing.
ST20099AE000
20099AE010
INSTALLER & REMOVER
Used for replacing the upper link bushing.
ST20099AE010
20099AE020
INSTALLER & REMOVER SET
Used for replacing the rear arm front bushing.
ST20099AE020
20099AE040
INSTALLER & REMOVER SET
Used for replacing the rear arm rear bushing.
ST20099AE040
RS-5
General Description
REAR SUSPENSION
ILLUSTRATION TOOL NUMBER 20099AE030 DESCRIPTION HELPER SOCKET WRENCH REMARKS Used for replacing helper.
ST20099AE030
20399AG000
STRUT MOUNT SOCKET
Used for removing and installing shock mount.
ST20399AG000
28099PA090
OIL SEAL PROTECTOR
Used for installing the rear drive shaft to the rear differential. For oil seal protection
ST28099PA090
28099PA100
REMOVER
Used for removal of DOJ.
ST28099PA100
2. GENERAL TOOL
TOOL NAME Alignment gauge Alignment gauge adapter Turning radius gauge Toe-in gauge Transmission jack Bearing puller Coil spring compressor REMARKS Used for measuring wheel alignment. Used for measuring wheel alignment. Used for measuring wheel alignment. Used for toe-in measurement. Used for removing and installing suspension. Used for removing bushings. Used for disassembling and assembling shock absorber.
RS-6
Wheel Alignment
REAR SUSPENSION
2. Wheel Alignment
A: INSPECTION
NOTE: Measure and adjust the front and rear wheel alignment at a time. Refer to FS section for measurement and adjustment of wheel alignment. <Ref. to FS-6, INSPECTION, Wheel Alignment.>
RS-7
Rear Stabilizer
REAR SUSPENSION
3. Rear Stabilizer
A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the stabilizer link.
B: INSTALLATION
1) Install in the reverse order of removal. CAUTION: Be sure to use a new self-locking nut. Ensure the stabilizer bushing and stabilizer have the same identification colors. To install the stabilizer bushing, align the paint mark end of stabilizer to the end of stabilizer bushing. The stabilizer bracket has a set orientation. Install it with the arrow mark facing the upper side of the vehicle.
RS-00038
3) Remove the stabilizer bracket.
(1) RS-00218
(1) Paint mark
RS-00217
2) Always tighten the stabilizer bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. Tightening torque: Stabilizer link 44 Nm (4.5 kgf-m, 32.5 ft-lb) Stabilizer bracket 38 Nm (3.9 kgf-m, 28 ft-lb)
C: INSPECTION
1) Check the bushing for abnormal fatigue or damage. 2) Check the stabilizer link for damage.
RS-8
Rear Arm
REAR SUSPENSION
4. Rear Arm
A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the sub frame support arm. <Ref. to RS-20, REMOVAL, Sub Frame Support Arm.> 3) Remove the bearing unit. <Ref. to DS-19, REMOVAL, Rear Hub Unit Bearing.> 4) Hang the back plate from sub frame.
7) Remove the bolts which secure the brake hose bracket to the rear arm. Remove the bolts which secure the ABS wheel speed sensor to the rear arm.
RS-00124
8) Remove the stabilizer link from the rear arm.
RS-00043
5) Remove the bolt which secures the parking brake cable clamp to the rear arm bracket.
RS-00044
9) Remove the shock absorber from the rear arm.
RS-00040
6) Remove the bolt which holds the brake hose bracket and ABS wheel speed sensor bracket to the rear arm.
RS-00045
10) Support the rear arm horizontally using a transmission jack.
RS-00041 RS-00046
RS-9
Rear Arm
REAR SUSPENSION
11) Remove the nuts which hold the rear arm to bracket. Remove the bolts and then remove the rear frame bracket.
14) Loosen the nut which holds the upper link to the rear arm.
RS-00050
15) Remove the bolt which secures the rear arm to the link, and then remove the rear arm.
B: INSTALLATION
CAUTION: Use a new bolt and self-locking nut. For parts which are not reusable, refer to COMPONENT. <Ref. to RS-3, REAR SUSPENSION, COMPONENT, General Description.> 1) Support the rear arm using a transmission jack. 2) Install the rear arm and temporarily tighten the bolts which hold the rear arm to the link. 3) Install the bearing unit. <Ref. to DS-20, INSTALLATION, Rear Hub Unit Bearing.> 4) Install the bolts which secure the ABS wheel speed sensor to rear arm. 5) Install the bolts which secure the brake hose to the rear arm. 6) Install bolts which secure the parking brake cable clamp to the rear arm bracket. 7) Set the vehicle equipped jack upside down, between the rear link and sub frame. Align the location of the jack, and with the rear shock absorber and rear arm attachment locations matched, temporarily tighten the bolt and nut. CAUTION: Protect the rear link and sub frame from being damaged by putting a waste cloth between the contact surface with the jack.
RS-00118
12) Loosen the nut which holds the front link to the rear arm.
RS-00048
13) Loosen the nut which holds the rear link to the rear arm.
RS-00049
RS-00051
8) Support the rear arm horizontally using a transmission jack.
RS-10
Rear Arm
REAR SUSPENSION
9) Tighten the nuts and bolts which hold the rear arm, front link, rear link, upper link and shock absorber. NOTE: Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground.
C: DISASSEMBLY
1. FRONT BUSHING
1) Set the ST A with the larger side of its inner diameter turned upward. 2) Set the rear arm with the protruding side of bushing turned upward. 3) Place the ST B on bushing, and push the bushing out. ST A 20099AE020 INSTALLER & REMOVER SET ST B 20099AE020 INSTALLER & REMOVER SET
(1) (2) RS-00052 ST-A ST-B (1)
(1) Rear arm (2) Transmission jack
10) Install the sub frame support arm. Tightening torque: Refer to COMPONENT of General Description for the tightening torque. <Ref. to RS-3, REAR SUSPENSION, COMPONENT, General Description.> 11) Inspect the wheel alignment and adjust if necessary.
RS-00119
(1) Bushing
2. REAR BUSHING
Using the ST C and bearing puller, press the rear bushing out. ST C 20099AE040 INSTALLER & REMOVER SET
ST-C
(1)
RS-00054
(1) Bearing puller
RS-11
Rear Arm
REAR SUSPENSION
D: ASSEMBLY
1. FRONT BUSHING
1) Set the ST A with the larger side of its inner diameter turned upward. 2) Set the rear arm with the vehicle inner side of arm turned downward. 3) Place the bushing on rear arm as shown in the figure. 4) Place the ST B on the bushing, and press-fit until each edge surface of bushing and rear arm is aligned. ST A 20099AE020 INSTALLER & REMOVER SET ST B 20099AE020 INSTALLER & REMOVER SET
2. REAR BUSHING
1) Insert the bushing into the bore of ST D. 2) Set the ST C, ST D and bearing puller in the specified positions as shown in the figure, and then press-fit the bushing until the outer end of bushing and rear end of rear arm is flat. ST C 20099AE040 INSTALLER & REMOVER SET ST D 20099AE040 INSTALLER & REMOVER SET
ST-C ST-D
(2) (1) RS-00056
E: INSPECTION
Check the rear arm for bending, corrosion or damage.
ST-B
ST-A
RS-00221
(1) 0r5 (2) Rubber protrusion: Assemble with the rubber protrusion side facing the arm inner side.
RS-12
Upper Link
REAR SUSPENSION
5. Upper Link
A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels. 2) Support the rear arm horizontally using a transmission jack.
B: INSTALLATION
1) Support the rear arm horizontally using a transmission jack. 2) Using new self-locking nuts, install the upper link.
(1) (1) (2) RS-00052 (2) RS-00052
3) Remove the bolt which secures the upper link to sub frame.
NOTE: Inspect the wheel alignment and adjust if necessary. Tightening torque: Upper link-to-Sub frame 57 Nm (5.8 kgf-m, 42 ft-lb) Upper link-to-Rear arm 65 Nm (6.6 kgf-m, 48 ft-lb)
C: DISASSEMBLY
Using the ST, press the bushing out. ST 20099AE010 INSTALLER & REMOVER
RS-00058
4) Remove the bolts which secure the upper link to the rear arm, and then remove the upper link.
ST
RS-00061
RS-00059
RS-13
Upper Link
REAR SUSPENSION
D: ASSEMBLY
Using the ST, press the bushing into place. ST 20099AE010 INSTALLER & REMOVER
ST
RS-00090
CAUTION: Outer side bushing has an orientation. Assemble it with the longer protrusion faced to the rear side of vehicle.
(2)
(3) (1) RS-00121
(1) Rear arm (2) Rear sub frame (3) Rear side of vehicle
E: INSPECTION
1) Visually check the upper link for abnormal fatigue or damage. 2) Visually check the bushing for abnormal fatigue or damage.
RS-14
Rear Shock Absorber

REAR SUSPENSION
6. Rear Shock Absorber

A: REMOVAL
1) Remove the luggage floor mat. (Wagon model) 2) Roll up the trunk side trim. (Sedan model) 3) Lift up the vehicle, and then remove the rear wheels. 4) Remove the bolts which secure the shock absorber to rear arm.
B: INSTALLATION
1) Support the shock absorber using a jack. 2) Using new self-locking nuts, secure the shock absorber to vehicle. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb) 3) Set the vehicle equipped jack upside down, between the rear link and sub frame. Adjust the position of the jack, and align the attachment position of the rear shock absorber and rear arm. Using new self-locking nuts, temporary tighten the bolt. CAUTION: Protect the rear link and sub frame from being damaged by putting a waste cloth between the contact surface with the jack.
RS-00065
5) Support the shock absorber using a jack. 6) Remove the nuts which secure the shock absorber mount to vehicle.
RS-00051
4) Support the rear arm horizontally using a transmission jack. 5) Using new self-locking nuts, tighten the bolt and nut which secures the shock absorber.
RS-00066
7) Remove the shock absorber.
(1) (2) RS-00052
Tightening torque: 62 Nm (6.3 kgf-m, 46 ft-lb) 6) Install the luggage floor mat. (Wagon model) 7) Set the trunk side trim. (Sedan model) 8) Check the wheel alignment and adjust it if necessary.
RS-15
Rear Shock Absorber

REAR SUSPENSION
C: DISASSEMBLY
Refer to Front Strut for disassembly procedure. <Ref. to FS-22, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut for installation procedures. <Ref. to FS-22, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to Front Strut for inspection procedures. <Ref. to FS-23, INSPECTION, Front Strut.>
F: DISPOSAL
CAUTION: Before handling the shock absorber, be sure to wear goggles to protect eyes from gas, oil and cutting powder. Do not disassemble the shock absorber or place it into a fire. Drill a hole into shock absorbers in case of discarding shock absorbers filled with gas. 1) Place the shock absorber on a level surface with the piston rod fully expanded. 2) Make a hole into the specified position 30 mm (1.18 in) deep using a drill with 2 3 mm (0.08 0.12 in) diameter.
(1) RS-00135
(1) 40 mm (1.57 in)
RS-16
Front Link
REAR SUSPENSION
7. Front Link
A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels. 2) Support the rear arm horizontally using a transmission jack.
B: INSTALLATION
1) Support the rear arm horizontally using a transmission jack. 2) Using new self-locking nuts, install the front link.
(1) (2) (1) (2) RS-00052 RS-00052
3) Remove the bolt which secures the front link to the sub frame.
CAUTION: Install the front link with the protruding side facing the front side of the vehicle.
(1)
RS-00075 RS-00072
(1) Front
4) Remove the bolt which secures the front link to rear arm, then remove the front link.
NOTE: Inspect the wheel alignment and adjust if necessary. Tightening torque: 57 Nm (5.8 kgf-m, 42 ft-lb)
C: INSPECTION
Visually check the front link for damage and deformation.
RS-00073
RS-17
Rear Link
REAR SUSPENSION
8. Rear Link
A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the rear stabilizer. <Ref. to RS-8, REMOVAL, Rear Stabilizer.> 3) Support the rear arm horizontally using a transmission jack.
B: INSTALLATION
1) Support the rear arm horizontally using a transmission jack. 2) Using new self-locking nuts, install the rear link. NOTE: Tighten the self-locking nut with the bolt head fixed in place when installing the adjusting bolt.
(1) (1) (2) RS-00052 RS-00052 (2)
4) Remove the bolts which secures the rear link to the rear arm.
Tightening torque: Rear link-to-Sub frame 120 Nm (12.2 kgf-m, 89 ft-lb) Rear link-to-Rear arm 57 Nm (5.8 kgf-m, 42 ft-lb) 3) Inspect the wheel alignment and adjust if necessary.
C: DISASSEMBLY
Using the ST A and ST B, press the bushing out. STA 20099AE000 INSTALLER & REMOVER STB 20099AE000 INSTALLER & REMOVER
RS-00080
5) Place alignment marks on the rear link adjusting bolt and sub frame. 6) Remove the bolt which secures the rear link to the sub frame, then remove the rear link. CAUTION: When loosening the adjusting bolt, make sure to fix the bolt head in place when loosening the nut.
ST-A
ST-B RS-00083
RS-00081
RS-18
Rear Link
REAR SUSPENSION
D: ASSEMBLY
Using the ST A and ST B, press-fit the bushing. STA 20099AE000 INSTALLER & REMOVER STB 20099AE000 INSTALLER & REMOVER
ST-A
ST-B RS-00083
E: INSPECTION
1) Visually check the rear link for abnormal fatigue or damage. 2) Visually check the bushing for abnormal fatigue or damage.
RS-19
Sub Frame Support Arm

REAR SUSPENSION
9. Sub Frame Support Arm

A: REMOVAL
1) Lift up the vehicle and support the rear sub frame with a support stand. 2) Remove the sub frame support arm.
RS-00088
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Sub frame support arm-to-Rear arm bracket 125 Nm (12.7 kgf-m, 92 ft-lb) Sub frame support arm-to-Rear sub frame 175 Nm (17.8 kgf-m, 129 ft-lb)
C: INSPECTION
Visually check the sub frame support arm for damage and deformation.
RS-20
Rear Sub Frame

REAR SUSPENSION
10.Rear Sub Frame

A: REMOVAL
1) Separate the front exhaust pipe and rear exhaust pipe. 2) Remove the rear exhaust pipe and muffler. 3) Remove the rear differential. T-type <Ref. to DI-30, REMOVAL, Rear Differential (Ttype).> VA-type <Ref. to DI-56, REMOVAL, Rear Differential (VAtype).> 4) Remove the rear stabilizer. <Ref. to RS-8, REMOVAL, Rear Stabilizer.> 5) Remove the bolts which secure the rear shock absorber to the rear arm. 6) Support the sub frame using a transmission jack.
B: INSTALLATION
1) Install in the reverse order of removal. 2) Follow the procedure below for the rear differential installation and tightening torque. T-type <Ref. to DI-32, INSTALLATION, Rear Differential (T-type).> VA-type <Ref. to DI-58, INSTALLATION, Rear Differential (VA-type).> 3) Support the rear arm horizontally using a transmission jack. Tighten the nuts and bolts which hold the rear arm, front link, rear link, upper link and shock absorber.
(1) (2) RS-00052

RS-00085
7) Remove the front link from sub frame. <Ref. to RS-17, REMOVAL, Front Link.> 8) Remove the rear link from the sub frame. <Ref. to RS-18, REMOVAL, Rear Link.> 9) Remove the upper link from the sub frame. <Ref. to RS-13, REMOVAL, Upper Link.> 10) Remove the sub frame support arm. 11) Remove the sub frame.
Tightening torque: Refer to COMPONENT of General Description for the tightening torque. <Ref. to RS-3, REAR SUSPENSION, COMPONENT, General Description.> 4) Check the wheel alignment and adjust it if necessary.
C: INSPECTION
Check the removed parts for wear, damage and crack, and repair or replace them if faulty.
RS-21
Helper
REAR SUSPENSION
11.Helper
A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the helper using the ST. ST 20099AE030 HELPER SOCKET WRENCH
ST
RS-00087
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb)
C: INSPECTION
Check the helper for major cracks or damages.
RS-22

REAR SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause (1) Permanent distortion or damaged coil spring (2) Rough operation of strut or shock absorber (3) Installation of the wrong strut or shock absorber (4) Installation of the wrong coil spring Corrective action Replace. Replace. Replace with proper parts. Replace with proper parts.
2. POOR RIDE COMFORT

1) Large rebound shock 2) Rocking of the vehicle continues too long after running over bump and hump. 3) Excessive shock in bumping
Possible cause (1) Damaged coil spring (2) Overinflation of tires (3) Improper wheel arch height (4) Fault in operation of strut or shock absorber (5) Damage or deformation of strut mount or shock absorber mount (6) Unsuitable length (maximum or minimum) of strut or shock absorber (7) Deformation or loss of bushing (8) Deformation or damage of helper in strut assembly or shock absorber (9) Oil leakage from the strut or shock absorber Corrective action Replace. Adjust. Adjust or replace the coil springs with new parts. Replace. Replace. Replace with proper parts. Replace. Replace. Replace.
3. NOISE
Possible cause (1) Wear or damage of strut or shock absorber component parts (2) Loosening of the suspension link installing bolt (3) Deformation or loss of bushing (4) Unsuitable length (maximum or minimum) of strut or shock absorber (5) Damaged coil spring (6) Wear or damage of the ball joint (7) Deformation of the stabilizer clamp Corrective action Replace. Tighten to the specified torque. Replace. Replace with proper parts. Replace. Replace. Replace.
RS-23

REAR SUSPENSION
RS-24
General Description
WHEEL AND TIRE SYSTEM
A: SPECIFICATION
1. WHEEL AND TIRE SIZE
WT-00001
(1) Offset (2) P.C.D. Offset mm (in) P.C.D. mm (in) Tire inflation pressure kPa (kgf/cm2, psi) Front wheel Rear wheel 230 (2.3, 33) 220 (2.2, 32) 240 (2.4, 35) 230 (2.3, 33) 100 (3.94) 220 (2.2, 32) 48 (1.89) 210 (2.1, 30) 220 (2.2, 32) 210 (2.1, 30) 230 (2.3, 33) 220 (2.2, 32)
Specification 2.5 i, - LTD 2.5 i Sedan 2.5 GT LTD, 3.0 R 2.5 GT spec. B 3.0 R LTD 2.5 i Wagon OUTBACK 2.5 i Base OUTBACK 2.5 i, -LTD, - LLB OUTBACK 2.5 XT OUTBACK 3.0 R LTD Spare tire
Tire size P205/50 R17 88V P205/50 R17 88V P205/55 R16 89V 215/45 R17 91W 215/45 R18 89Y P215/45 R18 89W P205/55 R16 89V P205/50 R17 88V P225/60 R16 97H P225/55 R17 95V T135/80R16 101M T135/70D17 102M T155/70D17 110M
Wheel size 17 7JJ 17 7JJ 16 6 1/2JJ 17 7JJ 18 7JJ 18 7JJ 16 6 1/2JJ 17 7JJ 16 6 1/2JJ 17 7JJ 16 4T 17 4T
55 (2.17)
50 (1.97) 40 (1.57) 420 (4.2, 60)
2. SERVICE DATA
Part Steel wheel Aluminum wheel Axial runout Radial runout 1.5 mm (0.059 in) 1.0 mm (0.039 in)
WT-2
General Description
3. ADJUSTING PARTS
Wheel balancing Dynamic unbalance Standard: Service limit 10 g (0.35 oz) or less
Balance weight part number (Knock-on type weight for steel wheels) 28101AA001 28101AA011 28101AA021 28101AA031 28101AA041 28101AA051 28101AA061 28101AA071 28101AA081 28101AA091 28101AA101 28101AA111 Balance weight part number (Knock-on type weight for aluminum wheel) 28101SA000 28101SA010 28101SA020 28101SA030 28101SA040 28101SA100 28101SA110 28101SA120 28101SA130 28101SA140 28101XA000 28101SA150
Weight 5 g (0.18 oz) 10 g (0.35 oz) 15 g (0.53 oz) 20 g (0.71 oz) 25 g (0.88 oz) 30 g (1.06 oz) 35 g (1.23 oz) 40 g (1.41 oz) 45 g (1.59 oz) 50 g (1.76 oz) 55 g (1.94 oz) 60 g (2.12 oz)
Balance weight part number (Adhesive type weight for aluminum wheel) 28101AE00B 28101AE01B 28101AE02B 28101AE03B 28101AE04B 28101AE05B 28101AE06B 28101AE07B 28101AE08B 28101AE09B 28101AE10B 28101AE11B 28101AE12B 28101AE13B 28101AE14B 28101AE15B 28101AE16B 28101AE17B 28101AE18B 28101AE19B 28101AE20B 28101AE21B 28101AE22B 28101AE23B 28101AE24B 28101AE25B 28101AE26B 28101AE27B 28101AE28B 28101AE29B 28101AE30B 28101AE31B 28101AE32B 28101AE33B 28101AE34B 28101AE35B 28101AE36B 28101AE37B 28101AE38B 28101AG50B 28101AG51B 28101AG52B 28101AG53B 28101AG54B 28101AG55B 28101AG56B 28101AG57B
Weight 5 g (0.18 oz) 7.5 g (0.26 oz) 10 g (0.35 oz) 12.5 g (0.44 oz) 15 g (0.53 oz) 17.5 g (0.62 oz) 20 g (0.71 oz) 22.5 g (0.79 oz) 25 g (0.88 oz) 27.5 g (0.97 oz) 30 g (1.06 oz) 32.5 g (1.15 oz) 35 g (1.23 oz) 37.5 g (1.32 oz) 40 g (1.41 oz) 42.5 g (1.50 oz) 45 g (1.59 oz) 47.5 g (1.68 oz) 50 g (1.76 oz) 52.5 g (1.85 oz) 55 g (1.94 oz) 57.5 g (2.03 oz) 60 g (2.12 oz) 62.5 g (2.20 oz) 65 g (2.29 oz) 67.5 g (2.38 oz) 70 g (2.47 oz) 72.5 g (2.56 oz) 75 g (2.65 oz) 77.5 g (2.73 oz) 80 g (2.82 oz) 82.5 g (2.91 oz) 85 g (3.00 oz) 87.5 g (3.09 oz) 90 g (3.17 oz) 92.5 g (3.26 oz) 95 g (3.35 oz) 97.5 g (3.44 oz) 100 g (3.53 oz) 102.5 g (3.62 oz) 105 g (3.70 oz) 107.5 g (3.79 oz) 110 g (3.88 oz) 112.5 g (3.97 oz) 115 g (4.06 oz) 117.5 g (4.14 oz) 120 g (4.23 oz)
WT-3
General Description
B: COMPONENT
T2
(1)
T1 (2)
(3)
(4)
WT-00131
(1) (2)
Tire pressure monitoring control module Screw
(3) (4)
Transmitter (Snap in type) Valve
Tightening torque:Nm (kgf-m, ft-lb) T1: 1.4 (0.14, 1) T2: 7.5 (0.76, 5.5)
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME Air pressure gauge Dial gauge with magnet stand Wheel balancer REMARKS Used for measuring tire air pressure. Used for measuring wheel runout. Used for adjusting wheel balance.
WT-4
Tire
2. Tire
A: INSPECTION
1) Take stones, glass, nails etc. out of the tread groove. 2) Replace tires in the following cases. CAUTION: When replacing a tire, make sure to use only tires of the same size, construction and load range as originally installed. Use a tire changer when removing the tire from the wheel. On models equipped with tire pressure monitoring systems, do not use the bead breaker in a 90 area centered on the transmitter to prevent damaging the transmitter.
(2) When the tread wear indicator appears as a solid band across the tread.
WT-00002
(1) Tread wear indicator (2) Tire tread
3) When a crack on tire valve is found, replace the tire valve.
1. TIRE ROTATION
Rotate tires periodically (12,500 km/7,500 miles) as shown in the figure, in order to prevent them from uneven wear and to prolong their life. Without instruction for the direction of tire rotation
(1) (2) WT-00070
(1) Transmitter (2) 90 (use of a bead breaker is prohibited in this area.)
To prevent damaging the transmitter, set the tire changer boom in the position as shown in the figure.
(2)
WT-00113
(1) Front
When the direction of tire rotation is specified

(4)
(3) (1) WT-00071
(1) (2) (3) (4)
Transmitter Direction of turn table rotation 90 Tire changer boom
WT-00115
(1) Front
(1) If large cracks on side wall, damage or cracks on the tread is found.
WT-5
Tire
NOTE: Vehicles equipped with tire pressure monitoring systems will require re-registration of transmitter ID. <Ref. to TPM(diag)-10, REGISTER TRANSMITTER ID, OPERATION, Subaru Select Monitor.>
WT-6
Steel Wheel
3. Steel Wheel
A: REMOVAL
1) Apply the parking brake, and position select lever or shift lever to P range (AT model) or 1st gear (MT model). 2) Set the shop jacks or a lift to the specified points, and support the vehicle with its wheels slightly contacting the floor. 3) Loosen the wheel nuts. 4) Raise the vehicle until its wheels are off the ground using the jack or a lift. 5) Remove the wheel nuts and wheels. NOTE: When removing the wheels, be careful not to damage the hub bolts. Place the wheels with their outer sides facing upward to prevent wheels from being damaged.
C: INSPECTION
1) Deformation or damage to the rim may cause air leakage. Check the rim flange for deformation, cracks or damage, and repair or replace as necessary. 2) Jack-up the vehicle until wheels clear the floor. 3) Slowly rotate the wheel to check rim runout using a dial gauge.
WT-00004
B: INSTALLATION
1) Remove dirt from the mating surface of the wheel and brake rotor. 2) Attach the wheel to the hub by aligning the wheel bolt holes with the hub bolts. 3) Temporarily attach the wheel nuts to the hub bolts. (In the case of aluminum wheels, use SUBARU genuine wheel nuts for aluminum wheels.) 4) Tighten the nuts by hand, making sure the wheel hub hole is aligned correctly to the guide portion of hub. 5) Tighten the wheel nuts in a diagonal selection to the specified torque. Use a wheel nut wrench. Wheel nut tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) CAUTION: Tighten the wheel nuts in two or three steps by gradually increasing the torque on opposing nuts, until they reach the specified torque. Do not push the wrench by foot. Always use both hands when tightening the nuts. Make sure the bolt, nut and the nut seating surface of the wheel are free from oil. 6) If a wheel is removed for replacement or for repair of a puncture, retighten the wheel nuts to the specified torque after driving 1,000 km (600 miles).
Rim runout:
Axial runout limit Vertical run-out limit 1.5 mm (0.059 in)
4) If the rim runout exceeds specifications, remove the tire from the wheel and check runout with the dial gauge attached to positions shown in the figure.
(1)
(1) (1)
WT-00005
(1) Approx. 7 mm (0.28 in)
5) If the measured runout still exceeds specifications, replace the wheel.
WT-7
Aluminum Wheel
4. Aluminum Wheel
A: REMOVAL
Refer to Steel Wheels for removal procedure of aluminum wheels. <Ref. to WT-6, REMOVAL, Steel Wheel.>
B: INSTALLATION
Refer to Steel Wheels for installation procedure of aluminum wheels. <Ref. to WT-6, INSTALLATION, Steel Wheel.>
C: INSPECTION
Refer to Steel Wheels for inspection procedure of aluminum wheels. <Ref. to WT-6, INSPECTION, Steel Wheel.> Rim runout:
Axial runout limit Vertical run-out limit 1.0 mm (0.039 in)
D: CAUTION
Aluminum wheels are easily scratched. To maintain their appearance and safety, be careful of the following: 1) Do not damage the aluminum wheels during removal, installation, wheel balancing, etc. After removing aluminum wheels, place them on a rubber mat etc. 2) When washing the aluminum wheel, use neutral synthetic detergent and water. Avoid using cleansers containing abrasives, hard brushes or an automatic car washer.
WT-8
Wheel Balancing
5. Wheel Balancing
A: ADJUSTMENT
NOTE: Because an adhesive type weight is adopted for the outside balance weight of 17-inch and 18-inch wheels, change the setting of the wheel balancer to adhesive type weight. 1) Remove the balance weights. CAUTION: Be careful not to damage the wheel. Completely remove the double-sided tape of the adhesive weight from the wheel. 2) Using the wheel balancer, measure wheel balance. 3) Select a weight close to the value measured by wheel balancer. CAUTION: Use SUBARU genuine balance weights.
Balance weight part number (Knock-on type weight for steel wheels) 28101AA001 28101AA011 28101AA021 28101AA031 28101AA041 28101AA051 28101AA061 28101AA071 28101AA081 28101AA091 28101AA101 28101AA111 Balance weight part number (Knock-on type weight for aluminum wheel) 28101SA000 28101SA010 28101SA020 28101SA030 28101SA040 28101SA100 28101SA110 28101SA120 28101SA130 28101SA140 28101XA000 28101SA150 Weight 5 g (0.18 oz) 10 g (0.35 oz) 15 g (0.53 oz) 20 g (0.71 oz) 25 g (0.88 oz) 30 g (1.06 oz) 35 g (1.23 oz) 40 g (1.41 oz) 45 g (1.59 oz) 50 g (1.76 oz) 55 g (1.94 oz) 60 g (2.12 oz)
Balance weight part number (Adhesive type weight for aluminum wheel) 28101AE00B 28101AE01B 28101AE02B 28101AE03B 28101AE04B 28101AE05B 28101AE06B 28101AE07B 28101AE08B 28101AE09B 28101AE10B 28101AE11B 28101AE12B 28101AE13B 28101AE14B 28101AE15B 28101AE16B 28101AE17B 28101AE18B 28101AE19B 28101AE20B 28101AE21B 28101AE22B 28101AE23B 28101AE24B 28101AE25B 28101AE26B 28101AE27B 28101AE28B 28101AE29B 28101AE30B 28101AE31B 28101AE32B 28101AE33B 28101AE34B 28101AE35B 28101AE36B 28101AE37B 28101AE38B 28101AG50B 28101AG51B 28101AG52B 28101AG53B 28101AG54B 28101AG51B 28101AG56B 28101AG57B
Weight 5 g (0.18 oz) 7.5 g (0.26 oz) 10 g (0.35 oz) 12.5 g (0.44 oz) 15 g (0.53 oz) 17.5 g (0.62 oz) 20 g (0.71 oz) 22.5 g (0.79 oz) 25 g (0.88 oz) 27.5 g (0.97 oz) 30 g (1.06 oz) 32.5 g (1.15 oz) 35 g (1.23 oz) 37.5 g (1.32 oz) 40 g (1.41 oz) 42.5 g (1.50 oz) 45 g (1.59 oz) 47.5 g (1.68 oz) 50 g (1.76 oz) 52.5 g (1.85 oz) 55 g (1.94 oz) 57.5 g (2.03 oz) 60 g (2.12 oz) 62.5 g (2.20 oz) 65 g (2.29 oz) 67.5 g (2.38 oz) 70 g (2.47 oz) 72.5 g (2.56 oz) 75 g (2.65 oz) 77.5 g (2.73 oz) 80 g (2.82 oz) 82.5 g (2.91 oz) 85 g (3.00 oz) 87.5 g (3.09 oz) 90 g (3.17 oz) 92.5 g (3.26 oz) 95 g (3.35 oz) 97.5 g (3.44 oz) 100 g (3.53 oz) 102.5 g (3.62 oz) 105 g (3.70 oz) 107.5 g (3.79 oz) 110 g (3.88 oz) 112.5 g (3.97 oz) 115 g (4.06 oz) 117.5 g (4.14 oz) 120 g (4.23 oz)
WT-9
Wheel Balancing
4) Install the selected weight to the point designated by the wheel balancer. CAUTION: Degrease the wheel surface where the adhesive type weight will be applied. Press the adhesive type weight by 25 N (2.5 kgf, 5.6 lb) or more per 5 g (0.18 oz) for 2 seconds or more and attain full adhesion. Total application of the adhesive type weight should be 100 g (3.53 oz) or less. The total weight of all adhesive weight on models with transmitters (tire pressure sensor) is to be 120 g (4.23 oz) or less. 5) Using the wheel balancer, measure the wheel balance again. Check that wheel balance is correctly adjusted. NOTE: Knock-on type balance weights for aluminum wheels can be used on any 15 to 18 inch aluminum wheels.
WT-00006
(1) Knock-on type weight for aluminum wheel (2) Knock-on type weight for steel wheel
Service limit A: Knock-on type weight for steel wheel: 5 25 g (0.18 0.88 oz) 2.0 mm (0.08 in) 30 g (1.06 oz) or more 1.8 mm (0.07 in) Knock-on type weight for aluminum wheel: 5 25 g (0.18 0.88 oz) 5.0 mm (0.20 in) 30 g (1.06 oz) or more 4.5 mm (0.177 in)
WT-10
T-type Tire
6. T-type Tire
A: NOTE
T-type tire for temporary use is equipped as a spare tire. CAUTION: Do not drive at a speed greater than 80 km/h (50 MPH). For the model with tire pressure monitoring system, the indicator light may blink when running with the T-type tire.
B: REPLACEMENT
Refer to Steel Wheels for removal and installation procedures of the T-type tire. <Ref. to WT-6, REMOVAL, Steel Wheel.> CAUTION: The T-type tire is only for temporary use. Replace with a conventional tire as soon as possible.
C: INSPECTION
1) Check the tire air pressure. Specifications: 420 kPa (4.2 kg/cm2, 60 psi) 2) Take stones, glass, nails, etc. out of the tread groove. 3) Check the tires for deformation, cracks, partial wear, or wear. CAUTION: Replace the tire with a new part if defective.
WT-11
Tire Pressure Monitoring System

7. Tire Pressure Monitoring System

A: REMOVAL
1. TRANSMITTER (SNAP IN TYPE)
1) Remove the wheels from the vehicle. <Ref. to WT-6, REMOVAL, Steel Wheel.> 2) Remove the tires from wheels. CAUTION: Use a tire changer when removing the tire from the wheel. 3) Loosen the screw to remove the transmitter from the valve. NOTE: Replace the valve and screw with a new part when reusing transmitter.
B: INSTALLATION
1. TRANSMITTER (SNAP IN TYPE)
CAUTION: Use the new transmitter assembly or replace the new valve and screw, when installing. 1) Replace the valve and screw with a new part when reusing transmitter.
(1) (2)
(3)
WT-00126 (3) (2) (1) (4)
(1) Screw (2) Transmitter (3) Valve
WT-00125
Tightening torque: 1.4 Nm (0.1 kgf-m, 1 ft-lb) 2) Install the transmitter to the wheel by aligning it with valve hole. 3) Install the tires to wheels. CAUTION: Use a tire changer when installing tire to wheel. To prevent damaging the transmitter, set the tire changer boom in the position as shown in the figure.
(2)
(1) (2) (3) (4)
Wheel Transmitter Screw Valve
4) Remove the valve stems from the wheel.
2. TIRE PRESSURE MONITORING CONTROL MODULE

1) Remove the drivers seat. <Ref. to SE-9, REMOVAL, Front Seat.> 2) Turn up the floor mat in the drivers seat area. 3) Remove the connector to remove tire pressure monitoring control module.
(4)
(3) (1) WT-00071
(1) (2) (3) (4)
Transmitter Direction of turn table rotation 90 Tire changer boom
WT-00073
4) Install the wheels to vehicle. <Ref. to WT-6, INSTALLATION, Steel Wheel.>
WT-12
Tire Pressure Monitoring System

5) Register the transmitter ID to the tire pressure monitoring control module. <Ref. to TPM(diag)-10, REGISTER TRANSMITTER ID, OPERATION, Subaru Select Monitor.>

C: ADJUSTMENT
Re-register the transmitter ID when transmitter has been replaced or tires have been rotated. <Ref. to TPM(diag)-10, REGISTER TRANSMITTER ID, OPERATION, Subaru Select Monitor.>
WT-13


A: INSPECTION
Symptom Wheel is out of balance. Possible cause Improperly inflated tire Uneven wear Front wheel alignment Rear wheel alignment Front strut Rear shock absorber Front axle Front hub unit bearing Rear hub unit bearing Vehicle is abnormally out of balance. Improperly inflated tire Uneven wear Front stabilizer Front wheel alignment Rear wheel alignment Abnormal wheel vibration Improperly inflated tire Uneven wear Improper wheel balancing Front axle Front hub unit bearing Rear hub unit bearing Abnormal tire wear Improperly inflated tire Improper wheel balancing Front wheel alignment Rear wheel alignment Corrective action Adjust the tire pressure. Check the tire referring to Abnormal tire wear in this table, carry out the procedure and replace the tire. Check the front wheel alignment. <Ref. to FS-6, INSPECTION, Wheel Alignment.> Check the rear wheel alignment. <Ref. to RS-7, INSPECTION, Wheel Alignment.> Check the front strut. <Ref. to FS-23, INSPECTION, Front Strut.> Check the rear shock absorber. <Ref. to RS-16, INSPECTION, Rear Shock Absorber.> Check the front axle. <Ref. to DS-16, INSPECTION, Front Axle.> Check the front hub unit bearing. <Ref. to DS-18, INSPECTION, Front Hub Unit Bearing.> Check the rear hub unit bearing. <Ref. to DS-21, INSPECTION, Rear Hub Unit Bearing.> Adjust the tire pressure. Check the tire referring to Abnormal tire wear in this table, carry out the procedure and replace the tire. Inspect the front stabilizer. <Ref. to FS-15, INSPECTION, Front Stabilizer.> Check the front wheel alignment. <Ref. to FS-6, INSPECTION, Wheel Alignment.> Check the rear wheel alignment. <Ref. to RS-7, INSPECTION, Wheel Alignment.> Adjust the tire pressure. Check the tire referring to Abnormal tire wear in this table, carry out the procedure and replace the tire. Check the wheel balance. <Ref. to WT-8, ADJUSTMENT, Wheel Balancing.> Check the front axle. <Ref. to DS-16, INSPECTION, Front Axle.> Check the front hub unit bearing. <Ref. to DS-18, INSPECTION, Front Hub Unit Bearing.> Check the rear hub unit bearing. <Ref. to DS-21, INSPECTION, Rear Hub Unit Bearing.> Adjust the tire pressure. Check the wheel balance. <Ref. to WT-8, ADJUSTMENT, Wheel Balancing.> Check the front wheel alignment. <Ref. to FS-6, INSPECTION, Wheel Alignment.> Check the rear wheel alignment. <Ref. to RS-7, INSPECTION, Wheel Alignment.>
WT-14

TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

A: PROCEDURE
CAUTION: Remove foreign matter (dust, water, oil etc.) from the tire pressure monitoring control module connector when removing or installing. NOTE: To check harness for open or short circuits, shake the suspected trouble spot or connector.
1 Step CHECK PRE-INSPECTION. 1) Check with the user regarding when the warning light lit or started blinking. 2) Before performing diagnostics, check all components which may adversely affect the tire pressure monitor system. <Ref. to TPM(diag)3, INSPECTION, General Description.> CHECK DIAGNOSTIC TROUBLE CODE (DTC). 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON and run the Subaru Select Monitor. NOTE: If the communication function of the Subaru Select Monitor cannot be executed normally, check the communication circuit. <Ref. to TPM(diag)-11, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.> 4) Read the DTC. <Ref. to TPM(diag)-16, OPERATION, Read Diagnostic Trouble Code (DTC).> PERFORM GENERAL DIAGNOSTICS. 1) Perform the inspection by referring to General Diagnostic Table. <Ref. to TPM(diag)-38, General Diagnostic Table.> 2) Perform the Clear Memory Mode. <Ref. to TPM(diag)-9, CLEAR MEMORY, OPERATION, Subaru Select Monitor.> 3) Perform the Inspection Mode. <Ref. to TPM(diag)-17, Inspection Mode.> 4) Read the DTC. <Ref. to TPM(diag)-8, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.> Check the DTC is not displayed. PERFORM DIAGNOSIS. 1) Refer to List of Diagnostic Trouble Code (DTC). 2) Correct the cause of trouble. 3) Perform the Clear Memory Mode. <Ref. to TPM(diag)-9, CLEAR MEMORY, OPERATION, Subaru Select Monitor.> 4) Perform the drive test. Drive the vehicle at 40 km/h (25 MPH) or faster for at least 10 minutes. 5) Read the DTC. <Ref. to TPM(diag)-8, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.> Check Yes Is the component that might Go to step 2. affect the tire pressure monitor system normal? No Repair or replace each component.
Is DTC displayed?
Go to step 4.
Go to step 3.
Does the tire pressure warning Finish the diagnolight illuminates for about 2 sec- sis. onds and then foes off after turning on the ignition switch, and then go out?
Check by referring to Diagnostic Procedure for TPM. <Ref. to TPM(diag)-14, WITHOUT DTC, INSPECTION, Subaru Select Monitor.>
Is DTC displayed?
Repeat steps 1 to 4 Finish the diagnosis. until DTC is not shown.
TPM(diag)-2
General Description
A: CAUTION
Airbag system wiring harness is routed near the TPM control module. CAUTION: All airbag system wiring harnesses are yellow. Do not use the electrical test equipment on these circuits. Be careful not to damage the airbag system wiring harness when servicing the tire pressure monitoring control module.
c. P225/60R16 and P225/55R17

Indoor temperature Temperature C (F) Ambient 1 (30) temperature Air Front 240 (35) pressure Rear 230 (33) kPa (psi) 15.5 (60) 12 (10) 23 (10) 255 (37) 245 (35) 270 (39) 260 (37)
B: INSPECTION
Before performing diagnosis, check the following item which might affect the quality of the tire pressure monitoring system.
1. TIRE
Inspect that the tire pressure is within the specification while the tire is cool. (Refer to Tire Caution Label.) Check the tires for damage or the insertion of foreign matters.

If the transmitter is replaced, ID registration for the transmitter is required. <Ref. to TPM(diag)-10, REGISTER TRANSMITTER ID, OPERATION, Subaru Select Monitor.> When adjusting tire pressure indoors in winter, there is a big temperature difference between the indoor facilities and outside. Once the car is outside where the temperature is lower, the air pressure in the tires will drop, causing the tire pressure warning light to illuminate, even if the pressure in the tires was adjusted to standard values indoors. To avoid this, it is necessary to adjust the tire pressure to the high side in consideration of the difference in temperature between inside and outside according to the following table. a. 215/45ZR17
Indoor Temperature temperature C (F) Ambient 1 (30) temperature Air Front 265 (38) pressure Rear 250 (36) kPa (psi) 15.5 (60) 12 (10) 23 (10) 280 (40) 265 (38) 295 (42) 280 (40)
2. BATTERY
Check that amount of battery fluid, gravity and voltage are within the specifications. Standard voltage: 12 V or more Specific gravity: 1.260 or more
b. 215/45R18 and P215/45R18, P205/50R17

Indoor Temperature temperature C (F) Ambient 1 (30) temperature Air Front 250 (36) pressure Rear 240 (35) kPa (psi) 15.5 (60) 12 (10) 23 (10) 265 (38) 255 (37) 280 (40) 270 (39)
TPM(diag)-3
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
2. GENERAL TOOL
TOOL NAME Circuit tester Transmitter registration tool REMARKS Used for measuring resistance, voltage and current. Used to register the transmitter ID. Manufacturer: Kent-Moore Item number: J45295
TPM(diag)-4


A: LOCATION
(2)
(3) (1)
(3)
TPM00029
(1)
Tire pressure monitoring control module
(2)
Tire pressure warning light
(3)
Snap-in type transmitter
(1)
TPM00002
(2)
TPM00003
(3)
TPM00049
TPM(diag)-5
Control Module I/O Signal

4. Control Module I/O Signal

Terminal No. 1 2 4 5 6 8 9 Measured value Select monitor communication Tire pressure warning light output Speed sensor signal Ignition power supply Battery power supply Body integrated unit (Hazard output signal) GND Measuring condition Serial communication Illuminate when malfunction occurs, or tire pressure decreases While driving (Pulse signal) IG switch ON (Battery voltage) Battery voltage 0 V (Always) Remarks System failure: blinks 25 times o illuminates Tire pressure decreases: turns on Change according to vehicle speed Always When hazard turns on. Always
TPM(diag)-6

B: WIRING DIAGRAM
(6)
(6)
(6)
(6)
(1) (4) (7)
6 (2)
2 5 (3) 1
(9)
(8)
(10)
(5)
1 2 3 4 5 6 7 8 9 10 11 12
TPM00005
(1) (2) (3)
Battery power supply Ignition power supply Tire pressure monitoring control module
(4) (5) (6) (7)
Antenna GND Transmitter Combination meter
(8) (9) (10)
Vehicle speed signal Subaru Select Monitor Body integrated unit
TPM(diag)-7


A: OPERATION
1) Prepare the Subaru Select Monitor kit. <Ref. to TPM(diag)-4, SPECIAL TOOL, PREPARATION TOOL, General Description.> 2) Connect the diagnosis cable to Subaru Select Monitor. 3) Connect the Subaru Select Monitor to data link connector. (1) Data link connector is located in the lower portion of instrument panel (on the drivers side).
8) On the Tire pressure monitor diagnosis display, select the {Diagnostic Code(s) Display}. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to TPM(diag)26, List of Diagnostic Trouble Code (DTC).> Display all the DTCs detected. If a particular DTC is not properly stored in memory (due to a voltage drop of the tire air pressure monitor control module power supply, etc.) when a problem occurs, a DTC suffixed with a question mark will appears on the Subaru Select Monitor display. This shows it may be an unreliable reading. 9) If communication is not possible between the tire pressure monitoring control module and the Subaru Select Monitor, check the communication circuit. <Ref. to TPM(diag)-11, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.> 10) When DTC is not displayed, check the indicator circuit and communication circuit. <Ref. to TPM(diag)-14, WITHOUT DTC, INSPECTION, Subaru Select Monitor.>
(1)
ABS00465
(1) Data link connector
(2) Connect the diagnosis cable to data link connector. CAUTION: Do not connect scan tools other than the Subaru Select Monitor. 4) Turn the ignition switch to ON (engine OFF) and run the Subaru Select Monitor. 5) On the Main Menu display, select the {Each System Check}. 6) On the System Selection Menu display, select the {Tire pressure monitor}. 7) After {Model Year} is displayed, select [OK].
TPM(diag)-8

2. DATA DISPLAY
1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Tire pressure monitor}. 3) After the {Tire pressure monitor} is displayed, select [OK]. 4) On the Tire pressure monitor diagnosis display, select the {Data Display}, and then necessary data will be displayed. A list of the support data is shown in the following table. 1. Data monitor (Analog)
Display Tire 1 FN code Tire 2 FN code Tire 3 FN code Contents to be displayed Unit of measure LEARN: Transmitted transmitter ID using the transmitter registration tool LOW BAT: Transmitter battery voltage running low OFF: Transmitter function stops (no data transmission) RE ME: Tire air changes r8.4 kPa WAKE: When data transmission is started from a stopped state. NORMAL: Conditions other than above kPa, psig, mmHg, inHg kPa, psig, mmHg, inHg kPa, psig, mmHg, inHg kPa, psig, mmHg, inHg km/h, MPH kPa, psig, mmHg, inHg kPa, psig, mmHg, inHg
LEARN, LOW BAT, OFF, WAKE, RE ME, NORMAL
Tire 4 FN code
Tire 1 air pressure Tire 2 air pressure Tire 3 air pressure Tire 4 air pressure Vehicle Speed Pressure warning Return pressure
Value converted to tire pressure from data delivered from transmitter is displayed. (The figure may differ from the actual measured values.) Vehicle speed signal which is input in control module. Threshold where tire pressure warning light illuminates Threshold where tire pressure warning light goes out
3. CLEAR MEMORY
1) On the Main Menu display, select the {2. Each System Check}. 2) On the System Selection Menu display, select the {Tire pressure monitor}. 3) After the {Tire pressure monitor} is displayed, select [OK]. 4) On the Tire pressure monitor diagnosis display, select the {Clearing Memory}. 5) When Done and Turn off the ignition switch. are shown on the display screen, end the Subaru Select Monitor and turn the ignition switch to OFF. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
TPM(diag)-9

4. REGISTER TRANSMITTER ID
Perform the procedures below to register the transmitter. Transmitter replaced. Replaced the tire pressure monitoring control module. NOTE: If registration of the transmitter ID is not possible after 2 attempts, replace the tire pressure monitoring control module. <Ref. to WT-11, TIRE PRESSURE MONITORING CONTROL MODULE, REMOVAL, Tire Pressure Monitoring System.> <Ref. to WT-12, TIRE PRESSURE MONITORING CONTROL MODULE, INSTALLATION, Tire Pressure Monitoring System.> During the registration, turn the ignition switch to OFF and end the Subaru Select Monitor. Or if the registration is not performed for 5 minutes or more, the registration mode is cancelled. When rotating tires, there is no affect on the performance or functions of the tire pressure monitoring control module even if the transmitter (ID) is not registered, however, the tire position displayed on the Subaru Select Monitor will be incorrect. 1) Adjust all tire pressures to the specifications. 2) Connect Subaru Select Monitor and select the {2. Each System Check} on the Main Menu. 3) On the System Selection Menu display, select the {Tire pressure monitor}. 4) After the {Tire pressure monitor} is displayed, select [OK]. 5) On the Tire pressure monitor diagnosis display, select the {Transmitter ID regist confirm}. 6) {ID registration mode When execute Registered ID is deleted. Continue?} is displayed, select [OK].
7) Touch the transmitter registration tool to the side wall area near the air valve on the front left tire, and press the switch. The transmitter ID is sent to the tire pressure monitoring control module. (At that time, the tire pressure warning light blinks to confirm that the registration has started.)
(1)
(2) TPM00006
(1) Air valve (transmitter) (2) Transmitter registration tool
NOTE: The registration order of transmitter ID is not specified. The transmitter registration tool is used by touching the side wall area near the transmitter. When registration of each tire is completed, the hazard light will blink and {ID registration completed} is displayed on the Select Monitor screen. If registration procedure stop in the halfway (turning ignition switch to OFF, wrong registration order, etc), proceed from step 5) 8) When ID registration is completed, the tire pressure warning light remains lit for approximately 2 seconds, to end the registration. Switch to the screen displaying the transmitter ID on the Subaru Select Monitor display. <Ref. to TPM(diag)-10, DISPLAY TRANSMITTER (ID)., OPERATION, Subaru Select Monitor.> 9) Check the transmitter ID that was registered, then perform a driving test. <Ref. to TPM(diag)-17, PROCEDURE, Inspection Mode.>
5. DISPLAY TRANSMITTER (ID)

1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Tire pressure monitor}. 3) After the {Tire pressure monitor} is displayed, select [OK]. 4) On the Tire pressure monitor diagnosis display, select the {Transmitter ID regist confirm}. 5) Select the {Transmitter ID data monitor} and then select [OK] to display the transmitter ID.
TPM(diag)-10

B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DETECTING CONDITION: Defective harness connector TROUBLE SYMPTOM: Communication is impossible between the tire pressure monitoring control module and the Subaru Select Monitor. WIRING DIAGRAM:
BATTERY
SBF-8
SBF-1
IGNITION RELAY DATA LINK CONNECTOR 16 7 No.4 B40 B97 R1 12 5 1
No.13
E
R211 TPM CONTROL MODULE
R211 1 2 3 4 5 6 7 8 9 10 11 12
B40
B97 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
TPM00024
TPM(diag)-11

Step CHECK IGNITION SWITCH. Check Is the ignition switch ON? Yes Go to step 2. No Turn the ignition switch to ON, and select TPM mode using Subaru Select Monitor. Charge or replace the battery. Go to step 4.
2 3
CHECK BATTERY. CHECK BATTERY TERMINAL.
Go to step 3.
Is there poor contact at battery Repair or tighten terminal? the battery terminal. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Go to step 8. MUNICATION. on the Subaru Select Monitor? 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to other systems can be executed normally. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Replace the tire MUNICATION. on the Subaru Select Monitor? pressure monitor1) Turn the ignition switch to OFF. ing control module. 2) Disconnect the tire pressure monitoring <Ref. to WT-11, control module connector. TIRE PRESSURE 3) Turn the ignition switch to ON. MONITORING 4) Check whether communication to other sysCONTROL MODtems can be executed normally. ULE, REMOVAL, Tire Pressure Monitoring System.> CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 7. EACH CONTROL MODULE AND DATA LINK more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the tire pressure monitoring control module. 3) Measure the resistance between data link connector and chassis ground. Connector & terminal (B40) No. 7 Chassis ground: CHECK TIRE PRESSURE MONITORING Is the voltage less than 1 V? Go to step 8. CONTROL MODULE OUTPUT SIGNAL. 1) Turn the ignition switch to ON. 2) Measure the voltage between tire pressure monitoring control module and chassis ground. Connector & terminal (B40) No. 7 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 :? Go to step 9. TIRE PRESSURE MONITORING CONTROL MODULE AND DATA LINK CONNECTOR. Measure the resistance between tire pressure monitoring control module and data link connector. Connector & terminal (R211) No. 1 (B40) No. 7: Is the tire pressure monitoring Go to step 10. CHECK TIRE PRESSURE MONITORING control module connector CONTROL MODULE CONNECTOR. Turn the ignition switch to OFF. inserted in the tire pressure monitoring control module until it locks?
Go to step 5.
Go to step 6.
Repair the harness and connector between each control module and data link connector.
Repair the harness and connector between each control module and data link connector. Repair the harness and connector between tire pressure monitoring control module and data link connector. Insert the tire pressure monitoring control module connector into the tire pressure monitoring control module.
TPM(diag)-12

Step Check CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 15 V? 1) Turn the ignition switch to ON. (engine OFF) 2) Measure the ignition power voltage between tire pressure monitoring control module connector and chassis ground. Connector & terminal (R211) No. 5 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 :? TIRE PRESSURE MONITORING CONTROL MODULE AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the tire pressure monitoring control module. 3) Measure the resistance of harness between tire pressure monitoring control module and chassis ground. Connector & terminal (R211) No. 9 Chassis ground: CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in tire pressure monitoring control module power supply, ground circuit and data link connector? Yes Go to step 11. No Repair open circuit of the harness between the tire pressure monitoring control module and battery. Repair open circuit of the harness of the tire pressure monitoring control module.
10
11
Go to step 12.
12
Repair the connec- Replace the tire tor. pressure monitoring control module. <Ref. to WT-11, TIRE PRESSURE MONITORING CONTROL MODULE, REMOVAL, Tire Pressure Monitoring System.>
TPM(diag)-13

2. WITHOUT DTC
DETECTING CONDITION: Defective combination meter Defective harness TROUBLE SYMPTOM: Tire pressure warning light does not go off. No diagnostic Code Present will be displayed on the Subaru Select Monitor. NOTE: When the tire pressure warning light is OFF and No diagnostic Code Present will be displayed on the Subaru Select Monitor, the system is in a normal condition. WIRING DIAGRAM:
TO POWER SUPPLY CIRCUIT FB-36 F/B FUSE NO.5 (IG) FB-17 F/B FUSE NO. 7 (B) FB-48 F/B FUSE NO. 4 (IG)
A3 COMBINATION METER A: B: i10

DRIVE CIRCUIT
TIRE INFLATION PRESSURE WARNING LIGHT
i11 MICRO COMPUTER B6 i102 16 R167
R211
TPM CONTROL MODULE
R211 1 2 3 4 5 6 7 8 9 10 11 12
B:
i11
i102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A: 1 2 3 4 5 11 12 13 14 15 16
i10 6 7 8 9 10 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TPM00042
TPM(diag)-14

Yes No Replace the tire Go to step 2. pressure monitoring control module. <Ref. to WT-11, TIRE PRESSURE MONITORING CONTROL MODULE, REMOVAL, Tire Pressure Monitoring System.> CHECK WIRING HARNESS. Is the resistance less than 0.5 :? Go to step 3. Repair the harness Measure the resistance between tire pressure and connector monitoring control module and combination between tire presmeter connector. sure monitoring Connector & terminal control module and (i11) No. 6 (R211) No. 2: combination meter. CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in the tire Repair the connec- Check the combipressure monitoring control tor. nation meter. module connector and combination meter connector? Step Check CHECK SUBARU SELECT MONITOR DATA. Is ON indicated? 1) Select {Current Data Display & Save} in Subaru Select Monitor. 2) Read the data of the Tire pressure warning light.
TPM(diag)-15


A: OPERATION
For details concerning DTC reading procedure, refer to Subaru Select Monitor. <Ref. to TPM(diag)8, Subaru Select Monitor.>
TPM(diag)-16
Inspection Mode
7. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition as much as possible. Drive the vehicle at 40 km/h (25 MPH) or faster for at least ten minutes.
TPM(diag)-17
Clear Memory Mode


A: OPERATION
For details concerning DTC clear operation, refer to Subaru Select Monitor. <Ref. to TPM(diag)-8, Subaru Select Monitor.>
TPM(diag)-18
Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern

9. Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern

A: INSPECTION
(4) (3) (2) (3) (2)
(1)
(6) (5)
(7)
(10) (10) (9) (19)
(9) (8)
(13)
(11)
(12)
(16) (14) (15) (17)
(19)
(18)
TPM00043
(1) (2) (3) (4) (5) (6) (7)
Ignition switch OFF ON Start Tire pressure Meet the specification Under the specification (refer to the following table.)
(8) (9) (10) (11) (12) (13)
Tire pressure warning light Light OFF Light ON System status Normal operation Malfunction
(14) (15) (16) (17) (18) (19)
Tire pressure warning light Light OFF Blink 1 second Blinks 25 times 2 seconds
TPM(diag)-19

Tire size P225/60 R16 97H P225/55 R17 95V P205/55 R16 89H P205/50 R17 88V 215/45 R18 89Y P215/45 R18 89W 215/45 R17 91W Air pressure 180 kPa (1.8 kgf/cm2, 26 psi), or less
186 kPa (1.86 kgf/cm2, 27 psi) or less
196 kPa (1.96 kgf/cm2, 28 psi) or less
1) When the tire pressure warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2) When tire pressure warning light does not go off, check the tire pressure monitoring control module/warning light circuit and the combination meter circuit. <Ref. to TPM(diag)-22, TIRE PRESSURE WARNING LIGHT DOES NOT COME OFF, Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern.> NOTE: If the problem is fixed while driving at approximately 40 km/h (25 MPH) after the tire pressure warning light blinks/lights, the warning light goes out and the tire pressure monitor system operates normally. (If there is a decrease in tire pressure, or a malfunction of the system, the malfunction history is displayed.)
TPM(diag)-20

B: TIRE PRESSURE WARNING LIGHT DOES NOT COME ON

DETECTING CONDITION: Defective combination meter TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), the tire pressure warning light does not come on (for approximately 2 seconds). WIRING DIAGRAM:

DRIVE CIRCUIT
R211
TPM CONTROL MODULE
R211 1 2 3 4 5 6 7 8 9 10 11 12
B:
i11
i102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A: 1 2 3 4 5 11 12 13 14 15 16
i10 6 7 8 9 10 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TPM00042
Step Check CHECK DIAGNOSTIC TROUBLE CODE Is diagnostics code (DTC) dis(DTC). played? Connect the Subaru Select Monitor, and read the Diagnostic Trouble Code. <Ref. to TPM(diag)-8, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.>
Yes Perform the diagnosis according to DTC. <Ref. to TPM(diag)-26, List of Diagnostic Trouble Code (DTC).>
No Replace the combination meter. <Ref. to IDI-22, REMOVAL, Combination Meter.>
TPM(diag)-21

C: TIRE PRESSURE WARNING LIGHT DOES NOT COME OFF

DETECTING CONDITION: Defective combination meter Tires pressure drop Transmitter ID not registered TROUBLE SYMPTOM: Tire pressure warning light remains illuminating after engine starts. WIRING DIAGRAM:

DRIVE CIRCUIT
R211
TPM CONTROL MODULE
R211 1 2 3 4 5 6 7 8 9 10 11 12
B:
i11
i102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A: 1 2 3 4 5 11 12 13 14 15 16
i10 6 7 8 9 10 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TPM00042
TPM(diag)-22

Step Check CHECK DIAGNOSTIC TROUBLE CODE Is DTC displayed? (DTC). Connect the Subaru Select Monitor, and read the Diagnostic Trouble Code. <Ref. to TPM(diag)-8, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.> CHECK TRANSMITTER (ID). Is the transmitter ID registered? Display the transmitter ID of the tire pressure monitor system. Yes No Perform the diag- Go to step 2. nosis according to DTC. <Ref. to TPM(diag)-26, List of Diagnostic Trouble Code (DTC).> Go to step 3.
Register the transmitter ID. <Ref. to TPM(diag)-10, REGISTER TRANSMITTER ID, OPERATION, Subaru Select Monitor.> Is the warning light output ON? Replace the tire CHECK TRANSMITTER DATA OUTPUT. Replace the com1) Select data display of the tire pressure monpressure monitor- bination meter. itoring. ing control module. <Ref. to IDI-22, 2) Start the engine and check the tire pressure <Ref. to WT-11, REMOVAL, Comwarning light output. TIRE PRESSURE bination Meter.> MONITORING CONTROL MODULE, REMOVAL, Tire Pressure Monitoring System.>
TPM(diag)-23

D: TIRE PRESSURE WARNING LIGHT IS 25 TIMES BLINKING AND TURN ON

DETECTING CONDITION: Tire pressure monitoring control module is faulty. Defective harness Transmitter is faulty. TROUBLE SYMPTOM: Every time the engine starts, tire pressure warning light blinks 25 times and then illuminates. WIRING DIAGRAM:

DRIVE CIRCUIT
R211
TPM CONTROL MODULE
R211 1 2 3 4 5 6 7 8 9 10 11 12
B:
i11
i102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A: 1 2 3 4 5 11 12 13 14 15 16
i10 6 7 8 9 10 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TPM00042
TPM(diag)-24

Step CHECK DIAGNOSTIC TROUBLE CODE (DTC). Connect the Subaru Select Monitor, and read the Diagnostic Trouble Code. <Ref. to TPM(diag)-8, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.> CHECK HARNESS. 1) Connect the Subaru Select Monitor to the terminal No. 2 of the tire pressure monitoring control module connector (R211). Connector & terminal (R211) No. 2 (+) Chassis ground (): 2) Turn the ignition switch to ON, and select Oscilloscope from the Main Menu of Subaru Select Monitor. 3) Check the voltage displayed. CHECK HARNESS. 1) Check the output waveform displayed in the oscilloscope of Subaru Select Monitor. Check Yes No Is diagnostics code (DTC) dis- Perform the diag- Go to step 2. played? nosis according to DTC. <Ref. to TPM(diag)-26, List of Diagnostic Trouble Code (DTC).> Is the voltage 10 V or more? Go to step 3. Go to step 4.
Is the pattern the same output waveform as shown in the figure? (1) 400r20 ms Duty 50 % High: Battery voltage Low:1.5 V or less
Check the combination meter.
High
Replace the tire pressure monitoring control module. <Ref. to WT-11, REMOVAL, Tire Pressure Monitoring System.>
Low (1) TPM00044
CHECK HARNESS. 1) Disconnect the tire pressure monitoring control module connector. 2) Connect the Subaru Select Monitor to the terminal No. 2 of the tire pressure monitoring control module connector (R211). Connector & terminal (R211) No. 2 (+) Chassis ground (): 3) Turn the ignition switch to ON, and select Oscilloscope from the Main Menu of Subaru Select Monitor. 4) Check the voltage displayed.
Replace the tire pressure monitoring control module. <Ref. to WT-11, REMOVAL, Tire Pressure Monitoring System.>
The harness between the combination meter connector and the tire pressure monitoring control module connector is shorted or open. Repair or replace the harness.
TPM(diag)-25


A: LIST
DTC 11 Item Tire 1 air pressure decrease Contents of diagnosis Tire pressure of tire 1 is reduced. Remarks <Ref. to TPM(diag)-28, DTC 11 TIRE 1 AIR PRESSURE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-28, DTC 12 TIRE 2 AIR PRESSURE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-28, DTC 13 TIRE 3 AIR PRESSURE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-29, DTC 14 TIRE 4 AIR PRESSURE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-29, DTC 21 TRANSMITTER 1 NO DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-29, DTC 22 TRANSMITTER 2 NO DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-29, DTC 23 TRANSMITTER 3 NO DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-30, DTC 24 TRANSMITTER 4 NO DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-31, DTC 31 TRANSMITTER 1 PRESSURE DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-31, DTC 32 TRANSMITTER 2 PRESSURE DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-31, DTC 33 TRANSMITTER 3 PRESSURE DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-32, DTC 34 TRANSMITTER 4 PRESSURE DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-33, DTC 41 TRANSMITTER 1 FUNCTION CODE ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-33, DTC 42 TRANSMITTER 2 FUNCTION CODE ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-33, DTC 43 TRANSMITTER 3 FUNCTION CODE ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
12
Tire 2 air pressure decrease
Tire pressure of tire 2 is reduced.
13
Tire pressure of tire 3 is reduced.
14
Tire pressure of tire 4 is reduced. Data cannot be received from transmitter 1. Data cannot be received from transmitter 2. Data cannot be received from transmitter 3. Data cannot be received from transmitter 4. Transmitter 1 data contents are abnormal.
21
Transmitter 1 no data
22
23
24
31
Transmitter 1 pressure data abnormal
32
Transmitter 2 data contents are abnormal.
33
34
41
Transmitter 1 function code abnormal
Function code has error.
42
43
TPM(diag)-26

DTC 44 Item Transmitter 4 function code abnormal Contents of diagnosis Function code has error. Remarks <Ref. to TPM(diag)-34, DTC 44 TRANSMITTER 4 FUNCTION CODE ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-35, DTC 51 TRANSMITTER 1 BATTERY VOLTAGE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-35, DTC 52 TRANSMITTER 2 BATTERY VOLTAGE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-35, DTC 53 TRANSMITTER 3 BATTERY VOLTAGE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-35, DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to TPM(diag)-36, DTC 61 VEHICLE SPEED IS ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
51
Transmitter 1 battery voltage decrease
Transmitter battery voltage is low.
52
53
54
Transmitter battery voltage is low. Vehicle speed signal is not input to the control module when the vehicle speed is 6 km/h (3.7 MPH) or more.
61
Vehicle speed is abnormal
TPM(diag)-27


A: DTC 11 TIRE 1 AIR PRESSURE DECREASE
NOTE: Refer to DTC 14 for diagnostic procedure. <Ref. to TPM(diag)-29, DTC 14 TIRE 4 AIR PRESSURE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B: DTC 12 TIRE 2 AIR PRESSURE DECREASE

C: DTC 13 TIRE 3 AIR PRESSURE DECREASE

TPM(diag)-28

D: DTC 14 TIRE 4 AIR PRESSURE DECREASE

DTC DETECTING CONDITION: Inflation pressure of tires dropped under specifications NOTE: For specification, refer to Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern. <Ref. to TPM(diag)-19, INSPECTION, Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern.> TROUBLE SYMPTOM: Tire pressure warning light illuminates.
1 Step CHECK TIRES. Lift up the vehicle and check for damage in the tires. CHECK TIRES. Check the tire air pressure. CHECK TRANSMITTER. Drive the vehicle at 40 km/h (25 MPH) or faster and compare the data from the transmitter on the four wheels. Yes Replace the tire. <Ref. to WT-5, Tire.> Is the tire pressure in the speci- Go to step 3. fications? Is there a transmitter with differ- Replace the transent data? mitter (tire pressure sensor). <Ref. to WT-11, Tire Pressure Monitoring System.> PERFORM DRIVING TEST. Is DTC displayed? Inspect using the 1) Perform the Clear Memory Mode. <Ref. to Diagnostic ProceTPM(diag)-9, CLEAR MEMORY, OPERATION, dure with DiagnosSubaru Select Monitor.> tic Trouble Code 2) Perform the driving test. <Ref. to (DTC). <Ref. to TPM(diag)-17, PROCEDURE, Inspection TPM(diag)-28, Mode.> Diagnostic Proce3) Read the DTC. <Ref. to TPM(diag)-8, READ dure with DiagnosDIAGNOSTIC TROUBLE CODE (DTC), tic Trouble Code OPERATION, Subaru Select Monitor.> (DTC).> Check Are there cracks or damage? No Go to step 2.
2 3
Adjust the air pressure. Go to step 4.
Finish the diagnosis.
CAUTION: When driving vehicle to perform driving test, there should be always 2 persons (driver and checker) to check.
E: DTC 21 TRANSMITTER 1 NO DATA

NOTE: Refer to DTC 24 for diagnostic procedure. <Ref. to TPM(diag)-30, DTC 24 TRANSMITTER 4 NO DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC 22 TRANSMITTER 2 NO DATA

G: DTC 23 TRANSMITTER 3 NO DATA

TPM(diag)-29

H: DTC 24 TRANSMITTER 4 NO DATA

DTC DETECTING CONDITION: Data from each transmitter is not received for 8 minutes. TROUBLE SYMPTOM: Tire pressure warning light blinks 25 times and then illuminates.
1 Step Check START FL TRANSMITTER. Is Latest reception ID 1) Connect the Subaru Select Monitor and updated? then turn the ignition switch to ON. 2) Select Transmit ID data monitor. <Ref. to TPM(diag)-10, DISPLAY TRANSMITTER (ID)., OPERATION, Subaru Select Monitor.> 3) Use the transmitter registration tool and transmit the ID from the FL transmitter to check Latest reception ID. CHECK FL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 1 registered ID. Is Latest reception ID START FR TRANSMITTER. Use the transmitter registration tool and trans- updated? mit the ID from the FR transmitter to check Latest reception ID. CHECK FR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 2 registered ID. Is Latest reception ID START RR TRANSMITTER. Use the transmitter registration tool and trans- updated? mit the ID from the RR transmitter to check Latest reception ID. CHECK RR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 3 registered ID. START RL TRANSMITTER. Is Latest reception ID Use the transmitter registration tool and trans- updated? mit the ID from the RL transmitter to check Latest reception ID. CHECK RL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 4 registered ID. CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this procedure? CHECK MALFUNCTION TRANSMITTER. Is there checked ID in the Check the registered ID of the transmitter indi- record? cated by DTC. Yes Go to step 2. No Replace front left transmitter.
Go to step 3.
Go to step 4.
Record the received ID update as the FL transmitter. Go to step 3. Replace the front right transmitter.
Go to step 5.
Go to step 6.
Record the received ID update as the FR transmitter. Go to step 5. Replace the RR transmitter.
Go to step 7.
Go to step 8.
Record the received ID update as the RR transmitter. Go to step 7. Replace the RL transmitter.
Go to step 9.
9 10
Go to step 10.
Record the received ID update as the RL transmitter. Go to step 9. Go to step 1.
Replace the trans- Replace the transmitter of the mitter showing the recorded position. latest ID that is not included in the registered IDs.
CAUTION: When driving vehicle to perform driving test, there should be always 2 persons (driver and checker) to check.
TPM(diag)-30

I:
DTC 31 TRANSMITTER 1 PRESSURE DATA ABNORMAL
NOTE: Refer to DTC 34 for diagnostic procedure. <Ref. to TPM(diag)-32, DTC 34 TRANSMITTER 4 PRESSURE DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC 32 TRANSMITTER 2 PRESSURE DATA ABNORMAL

K: DTC 33 TRANSMITTER 3 PRESSURE DATA ABNORMAL

TPM(diag)-31

L: DTC 34 TRANSMITTER 4 PRESSURE DATA ABNORMAL

DTC DETECTING CONDITION: When comparing the data from each transmitter to the previous data, the change is large. The pressure exceeds what the transmitter can measure. (Excessive pressure) TROUBLE SYMPTOM: Tire pressure warning light blinks 25 times and then illuminates.
1 Step Check START FL TRANSMITTER. Is Latest reception ID 1) Connect the Subaru Select Monitor and updated? then turn the ignition switch to ON. 2) Select Transmit ID data monitor. <Ref. to TPM(diag)-10, DISPLAY TRANSMITTER (ID)., OPERATION, Subaru Select Monitor.> 3) Use the transmitter registration tool and transmit the ID from the FL transmitter to check Latest reception ID. CHECK FL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 1 registered ID. START FR TRANSMITTER. Is Latest reception ID Use the transmitter registration tool and trans- updated? mit the ID from the FR transmitter to check Latest reception ID. CHECK FR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 2 registered ID. START RR TRANSMITTER. Is Latest reception ID Use the transmitter registration tool and trans- updated? mit the ID from the RR transmitter to check Latest reception ID. CHECK RR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 3 registered ID. START RL TRANSMITTER. Is Latest reception ID Use the transmitter registration tool and trans- updated? mit the ID from the RL transmitter to check Latest reception ID. CHECK RL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 4 registered ID. CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this procedure? CHECK MALFUNCTION TRANSMITTER. Is there checked ID in the Check the registered ID of the transmitter indi- record? cated by DTC. Yes Go to step 2. No Replace front left transmitter.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 7.
Go to step 8.
Go to step 9.
9 10
Go to step 10.
Record the received ID update as the RL transmitter. Go to step 9. Go to step 1.
Replace the trans- Replace the transmitter of the mitter showing the recorded position. latest ID that is not included in the registered IDs.
TPM(diag)-32

M: DTC 41 TRANSMITTER 1 FUNCTION CODE ABNORMAL

NOTE: Refer to DTC 44 for diagnostic procedure. <Ref. to TPM(diag)-34, DTC 44 TRANSMITTER 4 FUNCTION CODE ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
N: DTC 42 TRANSMITTER 2 FUNCTION CODE ABNORMAL

O: DTC 43 TRANSMITTER 3 FUNCTION CODE ABNORMAL

TPM(diag)-33

P: DTC 44 TRANSMITTER 4 FUNCTION CODE ABNORMAL

DTC DETECTING CONDITION: Unexpected function codes received from each transmitter. TROUBLE SYMPTOM: Tire pressure warning light blinks 25 times and then illuminates.
1 Step Check START FL TRANSMITTER. Is Latest reception ID 1) Connect the Subaru Select Monitor and updated? then turn the ignition switch to ON. 2) Select Transmit ID Monitor. <Ref. to TPM(diag)-10, DISPLAY TRANSMITTER (ID)., OPERATION, Subaru Select Monitor.> 3) Use the transmitter registration tool and transmit the ID from the FL transmitter to check Latest reception ID. CHECK FL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 1 registered ID. Is Latest reception ID START FR TRANSMITTER. Use the transmitter registration tool and trans- updated? mit the ID from the FR transmitter to check Latest reception ID. CHECK FR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 2 registered ID. Is Latest reception ID START RR TRANSMITTER. Use the transmitter registration tool and trans- updated? mit the ID from the RR transmitter to check Latest reception ID. CHECK RR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 3 registered ID. START RL TRANSMITTER. Is Latest reception ID Use the transmitter registration tool and trans- updated? mit the ID from the RL transmitter to check Latest reception ID. CHECK RL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 4 registered ID. CHECK MALFUNCTION TRANSMITTER. Is ID recorded by this procedure? Yes Go to step 2. No Replace front left transmitter.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 7.
Go to step 8.
Go to step 9.
10
CHECK MALFUNCTION TRANSMITTER. Is there checked ID in the Check the registered ID of the transmitter indi- record? cated by DTC.
Record the received ID update as the RL transmitter. Go to step 9. Go to step 10. Replace the transmitter indicated by DTC. Replace the trans- Replace the transmitter of the mitter indicated by recorded position. DTC.
TPM(diag)-34

Q: DTC 51 TRANSMITTER 1 BATTERY VOLTAGE DECREASE

NOTE: Refer to DTC 54 for diagnostic procedure. <Ref. to TPM(diag)-35, DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
R: DTC 52 TRANSMITTER 2 BATTERY VOLTAGE DECREASE

S: DTC 53 TRANSMITTER 3 BATTERY VOLTAGE DECREASE

T: DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE

DTC DETECTING CONDITION: Low battery signals received 20 times from each transmitter. TROUBLE SYMPTOM: Tire pressure warning light blinks 25 times and then illuminates.
1 Step Check CHECK TRANSMITTER. Is the fault eliminated? 1) Replace all transmitters with new parts and register their IDs. <Ref. to TPM(diag)-10, REGISTER TRANSMITTER ID, OPERATION, Subaru Select Monitor.> 2) Perform the Clear Memory Mode, and perform driving test. Yes No Internal battery of Replace the tire the transmitter had pressure monitorworn out. ing control module. <Ref. to WT-11, TIRE PRESSURE MONITORING CONTROL MODULE, REMOVAL, Tire Pressure Monitoring System.>
TPM(diag)-35

U: DTC 61 VEHICLE SPEED IS ABNORMAL

DTC DETECTING CONDITION: Vehicle speed function codes were received from the transmitter, but the vehicle speed signal was not input to the module. TROUBLE SYMPTOM: Tire pressure warning light blinks 25 times and then illuminates. WIRING DIAGRAM:
TO POWER SUPPLY CIRCUIT FB-17 F/B FUSE NO. 7 (B)
A1
MICRO COMPUTER SPEEDOMETER I/F A19
COMBINATION METER A: i10 VDC : MODEL WITH VDC ABS : MODEL WITHOUT VDC
18 i3 B38 ABS 23 i102 R167 4 12
VDC
R211
TPM CONTROL MODULE
B301
B310
ABS CONTROL MODULE
VDC CONTROL MODULE
R211 1 2 3 4 5 6 7 8 9 10 11 12
i102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A: 1 2 3 4 5 11 12 13 14 15 16
i10 6 7 8 9 10 17 18 19 20 21 22
B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B301 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 22 23 24 25
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
33
TPM00027
TPM(diag)-36

Step Check CHECK TIRE PRESSURE MONITORING Is the vehicle speed being CONTROL MODULE. input? 1) Connect an oscilloscope to the terminal No. 4 of the tire pressure monitoring control module connector (R211). 2) Drive the vehicle at 40 km/h (25 MPH) and check the vehicle speed signal at that time. Yes Replace the tire pressure monitoring control module. <Ref. to WT-11, TIRE PRESSURE MONITORING CONTROL MODULE, REMOVAL, Tire Pressure Monitoring System.> CHECK HARNESS. Is the resistance less than 0.5 :? Check the combi1) Disconnect the combination meter connecnation meter. <Ref. tor (i10). to IDI-22, 2) Connect the tire pressure monitoring control REMOVAL, Commodule connector (R211) and combination bination Meter.> meter connector (i10) and measure the resistance. No Go to step 2.
Repair or replace the open circuit of the harness.
TPM(diag)-37


A: INSPECTION
Symptoms Tire pressure warning light illuminates. Tire pressure is reduced. Problem parts Improper tire pressure adjustment. Punctured tire Air pressure sensor malfunction Air pressure sensor is out of battery. Tire pressure monitoring control module is faulty. Defective vehicle harness Defective combination meter
Tire pressure warning light blinks 25 times and then illuminates.
Tire pressure monitoring system has malfunction.
Tire pressure is dropping but the warning light does not illuminate.
Tire pressure warning light does not illuminate.
Air pressure sensor is faulty. Tire pressure monitoring control module is faulty. Defective combination meter
TPM(diag)-38
General Description
DIFFERENTIALS
A: SPECIFICATION
1. REAR DIFFERENTIAL
When replacing a rear differential assembly, select the correct one according to the following table. NOTE: Using a different rear differential assembly will cause the drive train and tires to drag or emit abnormal noise. For option codes, refer to the ID section. <Ref. to ID-2, IDENTIFICATION, Identification.>
Model Rear differential type Identification LSD type Type of gear Gear ratio (Number of gear teeth) Oil capacity Rear differential gear oil 2.5 L Non-turbo 5MT 4AT T-type VA1-type T1 XJ 3.900 (39/10) 4.111 (37/9) Sedan, Wagon 2.5 L Turbo 6MT 5MT T-type HY EW Torsen Hypoid gear 3.545 3.900 (39/11) (39/10) 1.0 2 (1.1 US qt, 0.9 Imp qt) GL-5 OUTBACK Model 5MT Rear differential type Identification LSD type Type of gear Gear ratio (Number of gear teeth) Oil capacity Rear differential gear oil JE Viscous coupling T2 T-type CD Viscous coupling 2.5 L Non-turbo 4AT TP 2.5 L Turbo 5MT 5AT CF 3.0 L VA2-type XU Viscous coupling 3.0 L 5AT VA2-type XZ XT Viscous coupling 3.083 (37/12)
XU
3.272 (36/11)
0.8 2 (0.8 US qt, 0.7 Imp qt)
0.8 2 (0.8 US qt, 0.7 Imp qt)
4.111 (37/9)
Hypoid gear 4.444 (40/9) 0.8 2 (0.8 US qt, 0.7 Imp qt) GL-5
3.272 (36/11)
DI-2
General Description
DIFFERENTIALS
2. IDENTIFICATION
Identification label positions are shown in the following figures. For details concerning identification, refer to the ID section. T-type
(1)
3. REAR DIFFERENTIAL GEAR OIL

Recommended gear oil: GL5 (75W90) CAUTION: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
(1) (2) (3) GL-5 (4) -30 -26 -15 -5 0 -22 -15 5 23 32 85W DI-00502 80W 75W -90 MT-00001
( C) ( F)
15 59
25 30 77 86 90
(1) Identification
VA1-type
(1)
(1) (2) (3) (4)
Item Rear differential gear oil API classification SAE viscosity No. and applicable temperature
DI-00396
(1) Identification
VA2-type
(1)
DI-00397
(1) Identification
DI-3
General Description
DIFFERENTIALS
4. SERVICE DATA
T-type (Except for GT spec. B Measure with spring measurement. 6MT model) (Measured from the companion T-type flange bolt) N (kgf, lbf) (GT spec. B 6MT model) Drive pinion bearing VA-type preload T-type (For new bearing) (Except for GT spec. B 6MT model) Measure with torque wrench Nm (kgf-m, ft-lb) T-type (GT spec. B 6MT model) VA-type T-type Side gear backlash mm (in) VA-type Side bearing standard width mm (in) T-type Hypoid driven gear to drive pinion backlash mm (in) VA-type Hypoid driven gear runout on its back surface mm (in) 17.7 38.8 (1.8 4.0, 4.0 8.7) 24.1 38.6 (2.5 3.9, 5.4 8.7) 12.7 32.2 (1.3 3.3, 2.9 7.2) 0.67 1.47 (0.07 0.15, 0.49 1.08) 0.91 1.46 (0.09 0.15, 0.67 1.08) 0.48 1.22 (0.05 0.12, 0.35 0.90) 0.10 0.20 (0.004 0.008) 0.05 0.15 (0.002 0.006) 20.00 (0.7874) 0.10 0.20 (0.004 0.008) 0.10 0.15 (0.004 0.006) 0.05 (0.002)
5. ADJUSTING PARTS
T-type (except for GT spec. B 6MT model)
Part No. 383695201 383695202 383695203 383695204 383695205 383695206 Part No. 383705200 383715200 383725200 383735200 383745200 383755200 383765200 383775200 383785200 383795200 383805200 383815200 383825200 383835200 383845200 Length mm (in) 56.2 (2.213) 56.4 (2.220) 56.6 (2.228) 56.8 (2.236) 57.0 (2.244) 57.2 (2.252) Thickness mm (in) 2.59 (0.1020) 2.57 (0.1012) 2.55 (0.1004) 2.53 (0.0996) 2.51 (0.0988) 2.49 (0.0980) 2.47 (0.0972) 2.45 (0.0965) 2.43 (0.0957) 2.41 (0.0949) 2.39 (0.0941) 2.37 (0.0933) 2.35 (0.0925) 2.33 (0.0917) 2.31 (0.0909)
Preload adjusting spacer
Preload adjusting washer
DI-4
General Description
DIFFERENTIALS
383495200 383505200 383515200 383525200 383535200 383545200 383555200 383565200 383575200 383585200 383595200 383605200 383615200 383625200 383635200 383645200 383655200 383665200 383675200 383685200 383445201 383445202 383445203 383475201 383475202 383475203 383475204 383475205 N (kgf, lb) 3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441) 0.75 0.80 (0.0295 0.0315) 0.80 0.85 (0.0315 0.0335) 0.85 0.90 (0.0335 0.0354) 0.20 (0.0079) 0.25 (0.0098) 0.30 (0.0118) 0.40 (0.0157) 0.50 (0.0197) 17.7 38.8 (1.8 4.0, 4.0 8.7)
Pinion height adjusting washer
Side gear thrust washer (Model without LSD)
Side retainer shim
Drive pinion bearing preload
Measure with spring measurement. (Measured from the companion flange bolt hole) Measure with torque wrench
Side gear backlash Hypoid driven gear to drive pinion backlash limit Hypoid driven gear runout limit on its back surface
Nm (kgf-m, ft-lb) 0.67 1.47 (0.07 0.15, 0.49 1.08) mm (in) 0.10 0.20 (0.004 0.008) mm (in) 0.10 0.20 (0.004 0.008) mm (in) 0.05 (0.002)
DI-5
General Description
DIFFERENTIALS
T-type (GT spec. B 6MT model)

Drive pinion bearing preload (For new bearing) Measure with spring measurement. (Measured from the companion flange bolt hole) N (kgf, lbf) Measured with torque wrench Nm (kgf-m, ft-lb) Part No. 31454AA130 31454AA140 31454AA150 31454AA160 31454AA170 31454AA180 Part No. 383705200 383715200 383725200 383735200 383745200 383755200 383765200 383775200 383785200 383795200 383805200 383815200 383825200 383835200 383845200 Part No. 38336AA230 38336AA240 38336AA250 38336AA260 38336AA270 38336AA280 38336AA290 38336AA300 38336AA310 38336AA320 38336AA330 38336AA340 38336AA350 38336AA360 38336AA370 38336AA380 38336AA390 38336AA400 38336AA410 38336AA420 24.1 38.6 (2.5 3.9, 5.4 8.7) 0.91 1.46 (0.09 0.15, 0.67 1.08) Length mm (in) 52.2 (2.055) 52.4 (2.063) 52.6 (2.071) 52.8 (2.079) 53.0 (2.087) 53.2 (2.094) Thickness mm (in) 2.59 (0.1020) 2.57 (0.1012) 2.55 (0.1004) 2.53 (0.0996) 2.51 (0.0988) 2.49 (0.0980) 2.47 (0.0972) 2.45 (0.0965) 2.43 (0.0957) 2.41 (0.0949) 2.39 (0.0941) 2.37 (0.0933) 2.35 (0.0925) 2.33 (0.0917) 2.31 (0.0909) Thickness mm (in) 3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441)
DI-6
General Description
DIFFERENTIALS
Side bearing standard width mm (in) Part No. 383475201 383475202 383475203 383475204 383475205 Limit mm (in) 20.00 (0.7874) Thickness mm (in) 0.20 (0.0079) 0.25 (0.0098) 0.30 (0.0118) 0.40 (0.0157) 0.50 (0.0197) 0.10 0.20 (0.004 0.008) 0.05 (0.002)
Side retainer shim
Hypoid driven gear to drive pinion backlash Driven gear rear face runout limit
DI-7
General Description
DIFFERENTIALS
VA1-type
Part No. 32288AA040 32288AA050 31454AA100 32288AA060 31454AA110 32288AA070 31454AA120 32288AA080 32288AA090 Part No. 38336AA000 38336AA120 38336AA010 38336AA130 38336AA020 38336AA140 38336AA030 38336AA150 38336AA040 38336AA160 38336AA050 38336AA170 38336AA060 38336AA180 38336AA070 38336AA190 38336AA080 38336AA200 38336AA090 38336AA210 38336AA100 38336AA220 38336AA110 32295AA200 32295AA210 32295AA220 32295AA230 32295AA240 32295AA250 803135011 803135012 803135013 803135014 803135015 N (kgf, lb) Length mm (in) 52.3 (2.059) 52.5 (2.067) 52.6 (2.071) 52.7 (2.075) 52.8 (2.079) 52.9 (2.083) 53.0 (2.087) 53.1 (2.091) 53.3 (2.098) Thickness mm (in) 1.500 (0.0591) 1.513 (0.0596) 1.525 (0.0600) 1.538 (0.0606) 1.550 (0.0610) 1.563 (0.0615) 1.575 (0.0620) 1.588 (0.0625) 1.600 (0.0630) 1.613 (0.0635) 1.625 (0.0640) 1.638 (0.0645) 1.650 (0.0650) 1.663 (0.0655) 1.675 (0.0659) 1.688 (0.0665) 1.700 (0.0669) 1.713 (0.0674) 1.725 (0.0679) 1.738 (0.0684) 1.750 (0.0689) 1.763 (0.0694) 1.775 (0.0699) 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108) 0.925 0.950 (0.0364 0.0374) 0.950 0.975 (0.0374 0.0384) 0.975 1.000 (0.0384 0.0394) 1.000 1.025 (0.0394 0.0404) 1.025 1.050 (0.0404 0.0413) 12.7 32.2 (1.3 3.3, 2.9 7.2)
Side gear thrust washer
Drive pinion bearing preload
Measure with spring measurement. (Measured from the companion flange bolt hole) Measure with torque wrench
Side gear backlash Hypoid driven gear to drive pinion backlash limit
Nm (kgf-m, ft-lb) 0.48 1.22 (0.05 0.12, 0.35 0.90) mm (in) 0.05 0.15 (0.002 0.006) mm (in) 0.10 0.15 (0.004 0.006)
DI-8
General Description
DIFFERENTIALS
VA2-type
Part No. 31454AA250 31454AA260 31454AA270 31454AA280 31454AA290 31454AA300 31454AA310 31454AA320 31454AA330 Part No. 38336AA430 38336AA440 38336AA450 38336AA460 38336AA470 38336AA480 38336AA490 38336AA500 38336AA510 38336AA520 38336AA530 38336AA540 38336AA550 38336AA560 38336AA570 38336AA580 38336AA590 38336AA600 38336AA610 38336AA620 38336AA630 38336AA640 38336AA650 32295AA350 32295AA360 32295AA370 32295AA380 32295AA390 32295AA400 Length mm (in) 51.05 (2.010) 51.25 (2.018) 51.35 (2.022) 51.45 (2.026) 51.55 (2.030) 51.65 (2.033) 51.75 (2.037) 51.85 (2.041) 52.05 (2.049) Thickness mm (in) 1.500 (0.0591) 1.513 (0.0596) 1.525 (0.0600) 1.538 (0.0606) 1.550 (0.0610) 1.563 (0.0615) 1.575 (0.0620) 1.588 (0.0625) 1.600 (0.0630) 1.613 (0.0635) 1.625 (0.0640) 1.638 (0.0645) 1.650 (0.0650) 1.663 (0.0655) 1.675 (0.0659) 1.688 (0.0665) 1.700 (0.0669) 1.713 (0.0674) 1.725 (0.0679) 1.738 (0.0684) 1.750 (0.0689) 1.763 (0.0694) 1.775 (0.0699) 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108)
Measure with spring measurement. (Measured from the companion flange bolt hole) Measure with torque wrench Hypoid driven gear to drive pinion backlash limit Drive pinion bearing preload
N (kgf, lb)
12.7 32.2 (1.3 3.3, 2.9 7.2)
Nm (kgf-m, ft-lb) 0.48 1.22 (0.05 0.12, 0.35 0.90) mm (in) 0.10 0.15 (0.004 0.006)
DI-9
General Description
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL WITHOUT LSD (T-TYPE)
(1) (2) (3) (4) (5) (19) (20) (23) (1) (21) (22) (25) T4 T1 (16) (15) (14) (13) (17) (31) (24) (30) (23) T2 (26) (27) (28) T3 T3 (18) (18) (19) (20) (21)
(29)
(6) (7)
T1 (13) (14) (15) (8) (9) (10) (11) (12) T5 DI-00260 (16) (17)
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Hypoid driven gear and drive pinion set Pinion height adjusting washer Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing Spacer Pilot bearing Front oil seal Companion flange Self-locking nut
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)
Side bearing O-ring Side retainer shim Side retainer Side oil seal Side gear thrust washer Side gear Pinion mate gear Pinion mate gear washer Pinion shaft lock pin Snap ring Pinion mate shaft Air breather cap
(26) (27) (28) (29) (30) (31)
Stud bolt Oil filler plug Oil drain plug Rear cover Differential case Gasket
Tightening torque:Nm (kgf-m, ft-lb) T1: 10.5 (1.1, 7.7) T2: 29.5 (3.0, 21.8) T3: 49 (5.0, 36.1) T4: 103 (10.5, 76.0) T5: 181.5 (18.5, 133.9)
DI-10
General Description
DIFFERENTIALS
2. REAR DIFFERENTIAL WITH LSD (T-TYPE)

(1) (2) (3) (4) (5)
(25)
(1) (21) (22)
T3
(23) T1 T4 (20)
T3 (24) T3
(15) (19) (13) (17) (16) (14) (14) (15) (7) (6) (18) T2
(25)
(13)
T1 (16) (8) (10) (12) (11) DI-00497 (9) (17)
T5
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)
Side bearing O-ring Side retainer shim Side retainer Side oil seal Gasket Differential case ASSY Rear cover Air breather cap Stud bolt Oil filler plug Oil drain plug Gasket (GT spec. B 6MT model)
Tightening torque:Nm (kgf-m, ft-lb) T1: 10.5 (1.1, 7.7) T2: 29.5 (3.0, 21.8) (Except for GT spec. B 6MT model) 44 (4.5, 32.5) (GT spec. B 6MT model) T3: 49 (5.0, 36.1) (Except for GT spec. B 6MT model) 60 (6.1, 44.3) (GT spec. B 6MT model) T4: 103 (10.5, 76.0) T5: 181.5 (18.5, 133.9)
DI-11
General Description
DIFFERENTIALS
3. REAR DIFFERENTIAL (VA1-TYPE)

(18) (19) (1) (19) (20)
(18)
(21)
(2) (3) (4) (5) T3
(17) (16) (15) (14) (30)

(24) (25) (23) (22)
T2
T1
(26)
(27)
(13) (6) (7)

(29) (13)
(28) (26)
T1
T1 (8) (9) (10) (12) T4 (11)
(14) (15) (16) (17)
DI-00296
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Lock plate Side bearing O-ring Side retainer Side oil seal Side gear thrust washer Side gear Pinion mate gear Pinion shaft lock pin Differential case Pinion mate shaft Air breather cap
(25) (26) (27) (28) (29) (30)
Stud bolt Gasket Oil filler plug Oil drain plug Rear cover Gasket
DI-12
General Description
DIFFERENTIALS
4. REAR DIFFERENTIAL (VA2-TYPE)
(1)
(2) (3) (4) (5) T4
(17) (16) (15) (14) (25) (23) T3 (22) (21) (7) (6) (13) T1 (14) (15) (8) (10) (12) (11) (9) (16) (17) (24) (21) T2 T1 (13) (19) (18) (20)
T5
DI-00559
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Hypoid driven gear and drive pinion set Pinion height adjusting washer Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing Spacer Pilot bearing Front oil seal
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)
Companion flange Self-locking nut Lock plate Side bearing O-ring Side retainer Side oil seal Differential case ASSY Air breather cap Stud bolt Gasket
(22) (23) (24) (25)
Oil filler plug Oil drain plug Rear cover Gasket
DI-13
General Description
DIFFERENTIALS
5. REAR DIFFERENTIAL MOUNTING SYSTEM
(4) T2
(3) (2)
(5)
(5)
(1) (5) T1
T3
DI-00350
(1) (2) (3)
Rear differential front member Rear differential member plate Rear differential ASSY
(4) (5)
Sub frame Self-locking nut
DI-14
General Description
DIFFERENTIALS
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine gear oil, grease or the equivalent. Do not mix gear oil, grease, etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Apply gear oil onto sliding or revolving surfaces before installation. Before installing the O-ring or snap ring, apply a sufficient amount of gear oil to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. Avoid damaging the mating surface of the case.
DI-15
General Description
DIFFERENTIALS
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 398477701 DESCRIPTION HANDLE REMARKS Used for installing the front and rear bearing cones.
ST-398477701
398477702
DRIFT
Used for press-fitting the bearing cone of differential carrier (front). For T-type
ST-398477702
398217700
ATTACHMENT SET
Stand for rear differential carrier disassembly and assembly.
ST-398217700
498447120
INSTALLER
Used for installing the front oil seal.
ST-498447120
DI-16
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 498427200 DESCRIPTION FLANGE WRENCH REMARKS Used for stopping rotation of companion flange when removing and tightening self-lock nut.
ST-498427200
398467700
DRIFT
Used for removing pinion, pilot bearing and front bearing cone. For T-type and VA1-type
ST-398467700
399780104
WEIGHT
Used for installing the front bearing cone and the pilot bearing companion flange.
ST-399780104
899580100
INSTALLER
Used for press-fitting the front bearing cone and pilot bearing.
ST-899580100
899904100
STRAIGHT PIN REMOVER
Used for driving out differential pinion shaft lock pin.
ST-899904100
DI-17
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 498247001 DESCRIPTION MAGNET BASE REMARKS Used for measuring backlash between side gear and pinion, and hypoid gear. Used together with DIAL GAUGE (498247100).
ST-498247001
498247100
DIAL GAUGE
Used for measuring backlash between side gear and pinion, and hypoid gear. Used together with the MAGNET BASE (498247001).
ST-498247100
398507704
BLOCK
Used for adjusting pinion height and preload. For T-type and VA1-type
ST-398507704
398177700
INSTALLER
Used for installing the rear bearing cone. For T-type and VA2-type
ST-398177700
398457700
ATTACHMENT
Used for removing the side retainer. For T-type
ST-398457700
DI-18
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 398477703 DESCRIPTION DRIFT 2 REMARKS Used for press-fitting bearing race (rear) of differential carrier. For T-type and VA2-type
ST-398477703
398437700
DRIFT
Used for installing the side oil seal. For T-type and VA2-type
ST-398437700
398507702
DUMMY SHAFT
Used for adjusting pinion height and preload. For T-type
ST-398507702
398507703
DUMMY COLLAR
Used for adjusting pinion height and preload. For T-type
ST-398507703
398517700
REPLACER
Used for removing rear bearing cone. For T-type and VA2-type
ST-398517700
DI-19
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 398487700 DESCRIPTION DRIFT REMARKS Used for press-fitting side bearing cone. For T-type and VA2-type
ST-398487700
398507701
DIFFERENTIAL CARRIER GAUGE
Used for adjusting pinion height. For T-type
ST-398507701
398527700
PULLER ASSY
Used for removing front oil seal. Used for removing side bearing cup. (T-type and VA1-type)
ST-398527700
28099PA090
OIL SEAL PROTECTOR
Used for installing the rear drive shaft to the rear differential. For oil seal protection
ST28099PA090
28099PA100
DRIVE SHAFT REMOVER
Used for removing the rear drive shaft from rear differential. For T-type
ST28099PA100
DI-20
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 399703600 DESCRIPTION PULLER ASSY REMARKS Used for removing companion flange.
ST-399703600
899874100
INSTALLER
Used for installing the companion flange.
ST-899874100
498077000
REMOVER
Used for removing the differential side bearing cone. For VA2-type
ST-498077000
899864100
REMOVER
Used for removing the differential side bearing.
ST-899864100
499277200
INSTALLER
Used for installing the front bearing cone. For VA2-type
ST-499277200
DI-21
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 18758AA000 DESCRIPTION PULLER REMARKS Used for removing side bearing cup. For VA2-type
ST18758AA000
18759AA000
PULLER ASSY
Used for removing the differential side bearing cone. For T-type
ST18759AA000
18678AA000
DUMMY SHAFT
Used for adjusting pinion height and preload. For VA2-type
ST18678AA000
18831AA010
Used for adjusting pinion height. For VA2-type
ST18831AA010
18630AA010
Used for removing and installing the side oil seal holder. For VA-type WRENCH ASSY (499787000) can also be used.
ST18630AA010
DI-22
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 498175500 DESCRIPTION INSTALLER REMARKS Used for installing the rear bearing cone. For VA1-type
ST-498175500
498447100
INSTALLER
Used for installing the oil seal. For VA1-type and T-type
ST-498447100
399520105
SEAT
Used for removing the side bearing cone. Used together with the PULLER SET (899524100). For VA-type
ST-399520105
498485400
DRIFT
Used for installing side bearing cone. For VA1-type
ST-498485400
498505501
Used for adjusting pinion height. For VA1-type
ST-498505501
DI-23
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 498447110 DESCRIPTION DRIFT REMARKS Used for press-fitting the bearing race (front) of the differential carrier. For VA1-type
ST-498447110
498447150
DUMMY SHAFT
Used for adjusting pinion height and preload. For VA1-type
ST-498447150
899524100
(1)
PULLER SET
Used for removing the differential side bearing cone. (1) Puller (2) Cap
(2)
ST-899524100
498515500
REPLACER
Used for removing rear bearing cone. For VA1-type
ST-498515500
499705404
SEAT
Used for removing the side bearing race. Used together with PULLER ASSY (499705401). For VA1-type
ST-499705404
DI-24
General Description
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER 499705401 DESCRIPTION PULLER ASSY REMARKS Used for removing the side bearing race. Used together with SEAT (499705404). For VA-type
ST-499705401
398417700
DRIFT
Used for installing side bearing race. For T-type and VA2-type
ST-398417700
498937110
HOLDER DRIVE PINION
Used for installing the pilot bearing. For T-type
ST-498937110
18674AA000
INSTALLER
Used for installing the rear bearing cone. For T-type
ST18674AA000
2. GENERAL TOOL
TOOL NAME Transmission jack Puller Thickness gauge Hexagon wrench Tire lever REMARKS Used for assembly/disassembly of the rear differential. Used for removing the side retainer. Used for measuring clearance. Used for installing and removing the filler and drain plug. Used for removing the rear drive shaft. (VA-type)
DI-25

DIFFERENTIALS

A: INSPECTION
1) Remove the filler plug, and then check the gear oil. Replace the gear oil if it is contaminated or deteriorated. <Ref. to DI-26, REPLACEMENT, Differential Gear Oil.> 2) Check that the gear oil level is within 5 mm (0.2 in) from the bottom of the filler plug hole. If the level is low, confirm that there is no oil leakage and refill up to the bottom of filler plug. NOTE: On VA1-types at factory settings, the oil level may be within 14 mm (0.6 in) from the bottom of the filler plug. This is at normal level, requiring no oil refill. T-type
(A)
VA2-type
(A) (B) DI-00355
(A) Filler plug (B) Oil drain plug
B: REPLACEMENT
1) Lift up the vehicle. 2) Remove the oil drain plug and filler plug, and drain the gear oil. CAUTION: Be careful not to burn your hands, because gear oil becomes extremely hot after running. T-type
(B) DI-00521 (B)
(A)
VA1-type
(A) DI-00356
VA1-type
(B) DI-00528 (A) (B)
DI-00505
DI-26

DIFFERENTIALS
VA2-type
(A)
T-type
(B) (A)
(B) DI-00357 DI-00391
3) Tighten the oil drain plug. NOTE: Apply liquid gasket to the drain plug for the Ttype (except for GT spec. B 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Use a new gasket for the VA-type and T-type (GT spec. B 6MT model). Tightening torque: T-type (except for GT spec.B 6MT model): 49 Nm (5.0 kgf-m, 36.1 ft-lb) T-type (GT spec. B 6MT model): 60 Nm (6.1 kgf-m, 44.3 ft-lb) VA1-type: 34 Nm (3.5 kgf-m, 25.1 ft-lb) VA2-type: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 4) Fill the differential carrier with gear oil to the bottom of filler plug. NOTE: Carefully refill oil while watching the level. Excessive or insufficient oil must be avoided. Recommended gear oil: <Ref. to DI-2, SPECIFICATION, General Description.> Oil capacity: Except for GT spec. B 6MT model: 0.8 2 (0.8 US qt, 0.7 Imp qt) GT spec. B 6MT model: 1.0 2 (1.1 US qt, 0.9 Imp qt)
VA1-type
(A)
(B) DI-00528
VA2-type
(A) (B) DI-00355
DI-27

DIFFERENTIALS
5) Install the filler plug. NOTE: Apply liquid gasket to the filler plug for the T-type (except for GT spec. B 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Use a new gasket for the VA-type and T-type (GT spec. B 6MT model). Tightening torque: T-type (except for GT spec.B 6MT model): 49 Nm (5.0 kgf-m, 36.1 ft-lb) T-type (GT spec. B 6MT model): 60 Nm (6.1 kgf-m, 44.3 ft-lb) VA1-type: 34 Nm (3.5 kgf-m, 25.1 ft-lb) VA2-type: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
DI-28

DIFFERENTIALS
3. Front Differential Assembly

A: NOTE
1. AT MODEL
4AT For front differential of 4AT model, refer to 4AT section. <Ref. to 4AT-95, Front Differential Assembly.> 5AT For front differential of 5AT model, refer to 5AT section. <Ref. to 5AT-92, Front Differential Assembly.>
2. MT MODEL
5MT For front differential for the 5MT model, refer to the 5MT section. <Ref. to 5MT-69, Front Differential Assembly.> 6MT For front differential for the 6MT model, refer to the 6MT section. <Ref. to 6MT-100, Front Differential Assembly.>
DI-29
Rear Differential (T-type)

DIFFERENTIALS
4. Rear Differential (T-type)

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Shift the select lever or gear shift lever to neutral. 4) Release the parking brake. 5) Loosen the wheel nuts. 6) Lift up the vehicle. 7) Remove the wheels. 8) Drain the differential gear oil. <Ref. to DI-26, REPLACEMENT, Differential Gear Oil.> 9) Remove the rear exhaust pipe and muffler. 2.5 L SOHC non-turbo model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> 2.5 L DOHC turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 10) Remove the heat shield cover.
13) Loosen the self-lock nuts which hold the rear differential to rear crossmember.
DI-00269
14) Remove the DOJ of rear drive shaft from rear differential using ST. ST 28099PA100 DRIVE SHAFT REMOVER
ST
(A)
DI-00270
(A) Bolt
15) Remove the rear differential front member.
AT-01331
11) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 12) Prepare the transmission jack and band.
DI-00358
16) Support the rear differential with the transmission jack.
DI-00268
DI-00273
17) Secure the rear differential using band. 18) Remove the self-lock nuts which hold the rear differential to the crossmember.
DI-30

DIFFERENTIALS
19) Remove the rear differential stud bolt from rear crossmember bushing. NOTE: When removing the stud bolt, carefully adjust the angle and location of transmission jack and jack stand, if necessary
23) Secure the rear drive shaft to lateral link using wire.
DI-00277
24) Remove the rear differential member plate from rear differential.
(A) DI-00400
20) Lower the transmission jack stand after removing the rear differential stud bolt from the rear crossmember. Rear drive shaft should not come into contact with the lateral link bolt.
DI-00359
(A) Rear differential member plate
DI-00392
21) Pull out the axle shaft from rear differential. NOTE: If it is difficult to remove the axle shaft from the rear differential, remove it using a ST. ST 28099PA100 DRIVE SHAFT REMOVER
DI-00276
22) Lower the transmission jack.
DI-31

DIFFERENTIALS
B: INSTALLATION
1) Install the rear differential member plate to the rear differential.
(A)
6) Push the rear differential to insert the axle shaft into rear differential.
DI-00281 DI-00359
7) Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear crossmember bushing properly.
2) Set the rear differential to transmission jack. NOTE: Secure the rear differential to transmission jack using band. 3) Attach the ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR
DI-00393 ST
8) After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.
DI-00279
4) Insert the spline shaft until the spline portion comes inside the side oil seal.
DI-00283
9) Tighten a new self-locking nut temporarily to rear crossmember.
DI-00280
5) Remove ST from rear differential.
DI-00269
DI-32

DIFFERENTIALS
10) Remove the band from rear differential. Lift up the rear differential until the rear differential is separated from the transmission jack. 11) Install the rear differential front member with a new self-locking nut. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 110 Nm (11.2 kgf-m, 81.1 ft-lb)
T2
16) Install the rear exhaust pipe and muffler. 2.5 L SOHC non-turbo model <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> 2.5 L DOHC turbo model <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 17) After installing the rear differential carrier to the vehicle, remove the filler plug, and refill with gear oil up to the lower lip of the plug hole. Oil capacity: Except for GT spec. B 6MT model: 0.8 2 (0.8 US qt, 0.7 Imp qt) GT spec. B 6MT model: 1.0 2 (1.1 US qt, 0.9 Imp qt)
T1 DI-00284
12) Tighten the self-locking nut. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A)
(B)
DI-00285
DI-00269
18) Tighten the filler plug. NOTE: Apply liquid gasket to the filler plug. (Except for GT spec. B 6MT model) Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Use a new gasket. (GT spec. B 6MT model) Tightening torque: Except for GT spec. B 6MT model: 49 Nm (5.0 kgf-m, 36.1 ft-lb) GT spec. B 6MT model: 60 Nm (6.1 kgf-m, 44.3 ft-lb) 19) Hereafter, install in the reverse order of removal.
13) Lower the transmission jack. 14) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 15) Install the heat shield cover.
AT-01331
DI-33

DIFFERENTIALS
C: DISASSEMBLY
To detect the real cause of trouble, inspect the following items before disassembling. Tooth contact and backlash of hypoid driven gear and drive pinion. Hypoid driven gear runout on its back surface Total preload of drive pinion 1) Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
4) Remove the bolts, and then remove the rear cover. NOTE: Remove by tapping with a plastic hammer.
(B)
(A)
DI-00063
(A) Rear cover (B) Differential carrier

ST DI-00061
2) Remove the oil drain plug and filler plug, and drain the gear oil. 3) Remove the air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
(A)
5) Keep the side retainers separate in order to easily identify RH and LH sides. Remove the side retainer mounting bolts, set the ST to differential case, and extract the side retainers RH and LH with a puller. NOTE: Side retainer shim of each side should be kept together with its mating retainer. ST 398457700 ATTACHMENT
ST
(B) DI-00064 DI-00062
6) Pull out the differential case assembly from differential carrier. NOTE: Be careful not to hit the teeth against the case.
(A) Air breather cap (B) Rear cover
DI-00065
DI-34

DIFFERENTIALS
7) When replacing the side bearing, remove the bearing cup from the side retainer using ST. ST 398527700 PULLER ASSY
10) Drive out the pinion shaft lock pin from the hypoid driven gear side. (Model without LSD) NOTE: The lock pin is staked at the pin hole end on the differential carrier. Do not drive it out forcibly before removing the stake. ST 899904100 STRAIGHT PIN REMOVER
ST
ST
DI-00066
8) Remove the bearing cone with ST. NOTE: Do not attempt to disassemble the parts unless necessary. Set the puller so that its claws catch the edge of the bearing cone. Store so that the right and left side bearing races and cones are not mixed together. ST 18759AA000 PULLER ASSY
ST
DI-00237
11) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers. (Model without LSD) NOTE: The gears should be marked or kept separated right and left, and front and rear as well as thrust washers.
DI-00316
9) Remove the hypoid driven gear by loosening hypoid driven gear bolts.
(A) (B) (C) (D) (E) Side gear Pinion mate gear Thrust washer Differential case Pinion mate shaft
DI-00238
DI-00068
DI-35

DIFFERENTIALS
12) Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
15) Remove the rear bearing cone from drive pinion by supporting the cone with ST. NOTE: Place the replacer so that its center-recessed side faces the pinion gear. ST 398517700 REPLACER
ST ST DI-00071
13) Extract the companion flange with a puller.

(A) DI-00074
16) Remove the front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
(A)
(B)
DI-00142
(A) Companion flange (B) PULLER
14) Press the end of drive pinion shaft and extract it together with rear bearing cone, pinion height adjusting washer and washer. NOTE: Hold the drive pinion so as not to drop it. ST 398467700 DRIFT
(B) DI-00145
(A) Differential carrier (B) Front oil seal
17) Remove the pilot bearing together with the front bearing cone and spacer using the ST. ST 398467700 DRIFT
ST
ST
DI-00073
(D)
(C)
(B)
(A) DI-00076
(A) (B) (C) (D)
Pilot bearing Spacer Front bearing Rear bearing cup
DI-36

DIFFERENTIALS
18) When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order using a brass bar.
(A)
1) Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with spacer and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted. (1) Install the rear bearing race (rear) into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477703 DRIFT 2
(B)
DI-00077
(A) 2 cutout portions along diagonal lines (B) Tap alternately with a brass bar.
D: ASSEMBLY
1. EXCEPT FOR GT SPEC. B 6MT MODEL
NOTE: Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply differential gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Use a new O-ring and gasket. Replace the oil seal with a new part at every disassembly. Apply differential gear oil to the oil seal lips. Be careful not to mix up the differential oil seal RH and LH.
ST2 ST1 DI-00079
(2) Install the rear bearing race (front) into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477702 DRIFT (3) Insert the ST1 into carrier with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: If tooth contact is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer. Use new rear bearing cone. (4) Install the preload adjusting spacer and washer, front bearing cone, ST2, companion flange, washer and self-locking nut. ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR
(A) (B) (C)
DI-00078 ST2 ST1
DI-00080
(A) Pinion height adjusting washer (B) Preload adjusting spacer (C) Preload adjusting washer
DI-37

DIFFERENTIALS
(5) Turn the ST1 by hand to smooth the bearing, and tighten the self-locking nut while measuring the initial load or initial torque with a spring scale or torque wrench. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque. NOTE: Use a new self-locking nut. Measure the preload in direction of tangent to the flange. Be careful not to give excessive preload. When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure. ST1 398507702 DUMMY SHAFT ST2 398507704 BLOCK Tightening torque: 181.5 Nm (18.5 kgf-m, 133.9 ft-lb)
Preload adjusting washer Part No. Thickness mm (in) 383705200 2.59 (0.1020) 383715200 2.57 (0.1012) 383725200 2.55 (0.1004) 383735200 2.53 (0.0996) 383745200 2.51 (0.0988) 383755200 2.49 (0.0980) 383765200 2.47 (0.0972) 383775200 2.45 (0.0965) 383785200 2.43 (0.0957) 383795200 2.41 (0.0949) 383805200 2.39 (0.0941) 383815200 2.37 (0.0933) 383825200 2.35 (0.0925) 383835200 2.33 (0.0917) 383845200 2.31 (0.0909) Preload adjusting spacer Part No. Length mm (in) 383695201 56.2 (2.213) 383695202 56.4 (2.220)
ST1 ST2
383695203 383695204 383695205 383695206
56.6 (2.228) 56.8 (2.236) 57.0 (2.244) 57.2 (2.252)
DI-00081
Initial load: 17.7 38.8 N (1.8 4.0 kgf, 4.0 8.7 lb)
2) Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. (1) Attach ST2. NOTE: At this time, install a provisionally selected or previously used pinion height adjusting washer. Measure and record the thickness. ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE ST3 398507703 DUMMY COLLAR
ST3 ST1 RH N ST2
DI-00117
Initial torque: 0.67 1.47 Nm (0.07 0.15 kgf-m, 0.49 1.08 ft-lb)
(A)
LH
DI-00083
N Measured value
DI-00481
(A) Pinion height adjusting washer
DI-38

DIFFERENTIALS
(2) Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST2. ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE
ST2
ST1
DI-00084
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one. T = To + N (H 0.01) 0.20 mm (0.008 in) NOTE: Use copies of this page.
T To N H Memo: Thickness of pinion height adjusting washer mm (in) Thickness of washer temporarily inserted mm (in) Clearance of thickness gauge mm (in) Figure marked on drive pinion head
Pinion height adjusting washer Part No. Thickness mm (in) 383495200 3.09 (0.1217) 383505200 3.12 (0.1228) 383515200 3.15 (0.1240) 383525200 3.18 (0.1252) 383535200 3.21 (0.1264) 383545200 3.24 (0.1276) 383555200 3.27 (0.1287) 383565200 3.30 (0.1299) 383575200 3.33 (0.1311) 383585200 3.36 (0.1323) 383595200 3.39 (0.1335) 383605200 3.42 (0.1346) 383615200 3.45 (0.1358) 383625200 3.48 (0.1370) 383635200 3.51 (0.1382) 383645200 3.54 (0.1394) 383655200 3.57 (0.1406) 383665200 3.60 (0.1417) 383675200 3.63 (0.1429) 383685200 3.66 (0.1441)
3) Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 398177700 INSTALLER
ST
DI-00085
(Example of calculation) To = 2.20 mm (0.0866 in) + 1.20 mm (0.0472 in) = 3.40 mm (0.1339 in) N = 0.23 mm (0.0091 in) H=+1 T = 3.40 mm (0.1339 in) + 0.23 mm (0.0091 in) 0.01 mm (0.0004 in) 0.20 mm (0.0079 in) = 3.42 mm (0.1346 in) Result: Thickness = 3.42 mm (0.1346 in) Therefore use washer 383605200.
4) Insert the drive pinion into the differential carrier, and install the preselected bearing preload adjusting spacer and washer.
(A) (B) (C)
(D)
DI-00086
(A) (B) (C) (D)
Drive pinion Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier
DI-39

DIFFERENTIALS
5) Press-fit the front bearing cone into case with ST1, ST2 and ST3. ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER
ST3 ST1
8) Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT
ST1
ST2 DI-00087 ST2 DI-00090
6) Insert the spacer, then press-fit the pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
ST2
9) Apply seal material on the drive pinion shaft thread and new self-locking nut seat. Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent 10) Attach a new self-locking nut and tighten using the ST. ST 498427200 FLANGE WRENCH Tightening torque: 181.5 Nm (18.5 kgf-m, 133.9 ft-lb)
ST1 DI-00088
7) Fit a new oil seal with ST. NOTE: Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply the differential gear oil to the oil seal lips. ST 498447120 INSTALLER
ST DI-00091 ST
11) Check the initial torque and initial load. Initial load: 17.7 38.8 N (1.8 4.0 kgf, 4.0 8.7 lb)
DI-00089
DI-00117
DI-40

DIFFERENTIALS
(1) Measure the side gear backlash. Side gear backlash: 0.10 0.20 mm (0.004 0.008 in)
DI-00481
DI-00240
12) Assembling differential case Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into the differential case. (Model without LSD) NOTE: Apply gear oil on both sides of the washer and on the side gear shaft before installing. Insert the pinion mate shaft into the differential case by aligning the lock pin holes.
(2) Adjust the backlash as specified by selecting the side gear thrust washers.
Part No. 383445201 383445202 383445203 Side gear thrust washer Thickness mm (in) 075 0.80 (0.0295 0.0315) 0.80 0.85 (0.0315 0.0335) 0.85 0.90 (0.0335 0.0354)
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust washer surfaces. (4) After inserting the pinion shaft lock pin into differential case, stake the both sides of the hole to prevent pin from falling off. 13) Install the driven gear to the differential case. NOTE: Before installing bolts, apply seal material to bolt threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent NOTE: Make sure there is no clearance between the differential case and driven gear. Tighten diagonally. Tightening torque: 103 Nm (10.5 kgf-m, 76.0 ft-lb)
DI-00239
DI-00068
DI-41

DIFFERENTIALS
14) Press the side bearing into differential case using ST. ST 398487700 DRIFT
(3) Install the side retainer shims and O-ring to retainers RH and LH on which they were installed. NOTE: Replace the O-ring with a new part. Replace broken or corroded side retainer shims with a new part of the same thickness.
Part No. 383475201 383475202 383475203 383475204 383475205 Side retainer shim Thickness mm (in) 0.20 (0.0079) 0.25 (0.0098) 0.30 (0.0118) 0.40 (0.0157) 0.50 (0.0197)
ST
DI-00095
15) Press-fit the side bearing race into side retainer using ST. ST 398417700 DRIFT
(4) When installing, align the arrow mark on the differential carrier with the mark on the side retainer. NOTE: Be careful that the bearing roller does not damage the side bearing race.
ST
DI-00324
16) Adjusting side retainer shims (1) The hypoid driven gear backlash and side bearing preload can be adjusted by the side retainer shim thickness. (2) Install the differential case assembly into differential carrier in the reverse order of disassembly. NOTE: Be careful not to hit the teeth against the case.
(A)
(B)
DI-00543
(A) Arrow mark (Side retainer side) (B) Arrow mark (Differential carrier side)
(5) Tighten the side retainer bolts. Tightening torque: 10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
DI-00065
DI-00487
DI-42

DIFFERENTIALS
(6) Measure the backlash between the hypoid driven gear and drive pinion. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. If the backlash is outside the standard range, adjust the side retainer shim by the following method. When backlash is less than 0.1 mm (0.004 in): Reduce the hypoid driven gear rear face shim thickness and increase the hypoid driven gear tooth surface side shim thickness. When backlash exceeds 0.2 mm (0.008 in): Increase the thickness of shim on the back side of the hypoid driven gear and reduce the thickness of shims on the teeth side of the hypoid driven gear. Backlash: 0.10 0.20 mm (0.004 0.008 in)
18) Check the hypoid driven gear runout on its back surface, and make sure that the pinion and hypoid driven gear rotates smoothly. If the hypoid driven gear runout on its back surface exceeds the specification, check for any foreign objects between the hypoid driven gear and differential case, and for any deformation of the case or gear. Hypoid driven gear runout on its back surface: 0.05 mm (0.002 in)
DI-00101
DI-00099
19) Checking and adjusting the tooth contact of hypoid driven gear (1) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear. (2) When the contact pattern is not correct, readjust. NOTE: Be sure to wipe off the lead-free red lead after the adjustment is completed. Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.)
(A)
(7) At the same time, measure the total preload of the drive pinion. Compared with the resistance when differential case is not installed, if the total preload is not within specification, adjust the thickness of side retainer shims, increasing/reducing both shims by an even amount at a time. Total preload: 20.7 54.4 N (2.1 5.5 kgf, 4.7 12.2 lb) 17) Recheck the hypoid driven gear to pinion backlash. Backlash: 0.10 0.20 mm (0.004 0.008 in)
(B)
MT-01401
DI-00099
DI-43

DIFFERENTIALS
AT-00208
AT-00210
AT-00212
AT-00213
AT-00209
AT-00211
AT-00213
AT-00212
DI-44

DIFFERENTIALS
20) If proper tooth contact is not obtained, readjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash. (1) Drive pinion height ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE
ST2
24) When installing, align the arrow mark on the differential carrier with the mark on the side retainer.
(A)
(B) ST1
DI-00543
DI-00084
T = To + N (H 0.01) 0.20 mm (0.008 in) Place: T = Thickness of pinion height adjusting washer mm (in) To = Thickness of washer temporarily inserted mm (in) N = Clearance of thickness gauge mm (in) H = Figure marked on drive pinion head (2) Hypoid gear backlash Backlash: 0.10 0.20 mm (0.004 0.008 in)
25) Apply liquid gasket to the bolt with arrow marks and install the side retainer bolt. Liquid gasket: THREE BOND 1110B (Part No. K0879Y0020) or equivalent Tightening torque: 10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
DI-00461
26) Install the new gasket and rear cover, and tighten the bolts to the specified torque. Tightening torque: 29.5 Nm (3.0 kgf-m, 21.8 ft-lb)
DI-00099
21) Remove the RH and LH side retainers. 22) Install new O-rings to side retainers of both sides. 23) Install oil seals to the side retainers on both sides. <Ref. to DI-88, REPLACEMENT, Rear Differential Side Oil Seal.>
DI-00490
DI-45

DIFFERENTIALS
27) Install the air breather cap.

(A)
2) Using the ST, press-fit the rear bearing race to the differential carrier. ST 398417700 DRIFT
(B)
ST
DI-00489
DI-00318
28) Install the oil drain plug and filler plug. Tightening torque: 49 Nm (5.0 kgf-m, 36.1 ft-lb)
3) Using the ST, press-fit the front bearing race to the differential carrier. ST 398477702 DRIFT
2. GT SPEC. B 6MT MODEL

NOTE: Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply differential gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Use a new O-ring and gasket. Be careful not to mix up the oil seal RH and LH. Replace the oil seal with a new part at every disassembly. Apply the differential gear oil between the lips when installing the oil seal.
DI-00319
4) Selection of pinion height adjusting washer (1) Measure the thickness of the inserted pinion height adjusting washer.
(2) Read the stamps of the attached drive pinion gear and a new part. NOTE: When there is no stamp, it indicates 0 (zero).
DI-00078
1) Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with spacer and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.
+2
DI-46
10
15
10
0 5
DI-00320
DI-00321

DIFFERENTIALS
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the installed washer with this one. T = T1 + (T2 0.01 T3 0.01)
T mm (in) T1 mm (in) T2 mm (in) T3 mm (in) Thickness of the selected pinion height adjusting washer Thickness of the inserted pinion height adjusting washer Numbers stamped on the attached drive pinion gear Numbers stamped on a new drive pinion gear
6) Insert the drive pinion into the differential carrier, and install the originally attached bearing preload adjusting spacer and washer.
(A) (B) (C)
(Example of calculation) T1 = 3.30 mm (0.1299 in), T2 = +2, T3 = 1 T = 3.30 mm (0.1299 in) + {(2 0.01) (1 0.01)} = 3.33 mm (0.1311 in) Result: Thickness = 3.33 mm (0.1311 in) A washer to be used is 38336AA310.
Pinion height adjusting washer Part No. Thickness mm (in) 38336AA230 3.09 (0.1217) 38336AA240 3.12 (0.1228) 38336AA250 3.15 (0.1240) 38336AA260 3.18 (0.1252) 38336AA270 3.21 (0.1264) 38336AA280 3.24 (0.1276) 38336AA290 3.27 (0.1287) 38336AA300 3.30 (0.1299) 38336AA310 3.33 (0.1311) 38336AA320 3.36 (0.1323) 38336AA330 3.39 (0.1335) 38336AA340 3.42 (0.1346) 38336AA350 3.45 (0.1358) 38336AA360 3.48 (0.1370) 38336AA370 3.51 (0.1382) 38336AA380 3.54 (0.1394) 38336AA390 3.57 (0.1406) 38336AA400 3.60 (0.1417) 38336AA410 3.63 (0.1429) 38336AA420 3.66 (0.1441)
(D)
DI-00086
(A) (B) (C) (D)
7) Insert the spacer, then press-fit the pilot bearing with the ST. ST1 399780104 WEIGHT ST2 899580100 INSTALLER ST3 398507703 DUMMY COLLAR ST4 498937110 HOLDER DRIVE PINION
ST2 ST4 ST3 ST1 ST4 ST1 DI-00322
8) Press-fit the companion flange with ST1, ST2 and ST3. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT ST3 498937110 HOLDER DRIVE PINION
5) Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 18674AA000 INSTALLER
ST1 ST3
ST2 ST2
ST
DI-00323
DI-00085
DI-47

DIFFERENTIALS
9) Install the self-locking nut. Tighten using the ST. ST 498427200 FLANGE WRENCH Tightening torque: 181.5 Nm (18.5 kgf-m, 133.9 ft-lb)
11) If the bearing preload is outside the specification range, select a preload adjusting washer and spacer from the table below to fit within the specification range.
Preload adjusting washer Part No. Thickness mm (in) 383705200 2.59 (0.1020) 383715200 2.57 (0.1012) 383725200 2.55 (0.1004) 383735200 2.53 (0.0996) 383745200 2.51 (0.0988) 383755200 2.49 (0.0980) 383765200 2.47 (0.0972) 383775200 2.45 (0.0965) 383785200 2.43 (0.0957) 383795200 2.41 (0.0949) 383805200 2.39 (0.0941) 383815200 2.37 (0.0933) 383825200 2.35 (0.0925) 383835200 2.33 (0.0917) 383845200 2.31 (0.0909) Preload adjusting spacer Part No. Length mm (in) 31454AA130 52.2 (2.055) 31454AA140 52.4 (2.063) 31454AA150 31454AA160 31454AA170 31454AA180 52.6 (2.071) 52.8 (2.079) 53.0 (2.087) 53.2 (2.094)
ST DI-00091
10) Turn the drive pinion shaft 10 or more times to make it fit in each taper roller bearing, and measure the initial load or initial torque. Initial load: 24.1 38.6 N (2.5 3.9 kgf, 5.4 8.7 lb)
DI-00117
DI-00481 ST DI-00091
DI-48

DIFFERENTIALS
13) Draw out the companion flange with a puller.

(A)
16) Install the self-locking nut. Tighten using the ST. ST 498427200 FLANGE WRENCH
(B)
DI-00142 ST DI-00071
(A) Companion flange (B) Puller
14) Install a new oil seal using ST. NOTE: Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply the differential gear oil between the oil seal lips. ST 498447120 INSTALLER
ST DI-00117
DI-00089
15) Press-fit the companion flange with ST1, ST2 and ST3. ST1 899874100 INSTALLER ST2 399780104 WEIGHT ST3 498937110 HOLDER DRIVE PINION NOTE: Be careful not to damage the bearing.
DI-00481
ST1 ST3
ST2 ST2
DI-00323
DI-49

DIFFERENTIALS
18) Install the driven gear to the differential case. NOTE: Before installing bolts, apply seal material to bolt threads. Tighten diagonally. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 103 Nm (10.5 kgf-m, 76.0 ft-lb)
21) Adjusting side retainer shims (1) The driven gear backlash and side bearing preload can be adjusted by the side retainer shim thickness. (2) Install the differential case assembly into differential carrier in the reverse order of disassembly. NOTE: Be careful not to hit the teeth against the case.
DI-00065 DI-00068
(3) Install the side retainer shims and O-rings to retainers RH and LH from which they were removed. NOTE: Replace the O-ring with a new part. Replace broken or corroded side retainer shims with a new part of the same thickness.
Part No. 383475201 383475202 383475203 383475204 383475205 Side retainer shim Thickness mm (in) 0.20 (0.0079) 0.25 (0.0098) 0.30 (0.0118) 0.40 (0.0157) 0.50 (0.0197)
ST
DI-00095
20) Assembling the side retainer (1) Using the ST and a press, press-fit the side bearing outer race. ST 398417700 DRIFT
(4) When installing, align the arrow mark on the differential carrier with the mark on the side retainer. NOTE: Be careful that side bearing outer race is not damaged by the bearing roller.
ST
DI-00324
(A)
(2) Install the oil seal. <Ref. to DI-88, REPLACEMENT, Rear Differential Side Oil Seal.>
(B)
DI-00543
DI-50

DIFFERENTIALS
(5) Tighten the side retainer bolts. Tightening torque: 10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
22) Measure the backlash between the hypoid driven gear and drive pinion again. Backlash: 0.10 0.20 mm (0.004 0.008 in)
DI-00487
(6) Measure the backlash between the hypoid driven gear and drive pinion. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. If the backlash is outside the standard range, adjust the side retainer shim by the following method. When backlash is less than 0.1 mm (0.004 in): Reduce the hypoid driven gear back surface shim thickness and increase the hypoid driven gear tooth surface side shim thickness. When backlash exceeds 0.2 mm (0.008 in): Increase the thickness of shim on the back side of the hypoid driven gear and reduce the thickness of shims on the teeth side of the hypoid driven gear. Backlash: 0.10 0.20 mm (0.004 0.008 in)
DI-00099
23) Check the hypoid driven gear runout on its back surface, and make sure that the pinion and hypoid driven gear rotates smoothly. If the hypoid driven gear runout on its rear face exceeds the limit, check for any foreign objects between hypoid driven gear and differential case, and for any deformation of the case or gear. Driven gear rear face runout limit: 0.05 mm (0.002 in)
DI-00101
24) Checking and adjusting the tooth contact of hypoid driven gear (1) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Rotate the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear, and check the contact pattern.
DI-00099
(7) At the same time, measure the total preload of the drive pinion. Compared with when differential case is not installed, if the total preload is not within specification, adjust the thickness of side retainer shims, by increasing/reducing both shims by an even amount at a time. Total preload: 27.0 54.0 N (2.8 5.5 kgf, 6.1 12.1 lb)
DI-51

DIFFERENTIALS
(2) When the contact pattern is not correct, readjust. NOTE: Be sure to wipe off the lead-free red dye after the adjustment is completed. Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.)
(A)
AT-00209
(B)
MT-01401
AT-00213
AT-00208
AT-00210
AT-00212
AT-00213
DI-52

DIFFERENTIALS
28) Apply liquid gasket to the bolts indicated by arrows, and tighten the side retainer bolt. Liquid gasket: THREE BOND 1110B (Part No. K0879Y0020) or equivalent Tightening torque: 10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
AT-00211
DI-00461
29) Install the new gasket and rear cover, and tighten the bolts to specified torque. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
AT-00212
25) If proper tooth contact is not obtained, readjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash. 26) Install oil seals to the side retainers on both sides. <Ref. to DI-88, REPLACEMENT, Rear Differential Side Oil Seal.> 27) When installing, align the arrow mark on the differential carrier with the mark on the side retainer.
DI-00560
30) Install the breather cap. 31) Install the oil drain plug and filler plug. Tightening torque: 60 Nm (6.1 kgf-m, 44.3 ft-lb)
(A)
(B)
DI-00543
DI-53

DIFFERENTIALS
E: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary. 1) Hypoid driven gear and drive pinion If there is evidently an abnormal tooth contact, find out the cause and adjust until the teeth contact correctly. Replace the gear if there is an excessive worn or an incapable adjustment. If crack, cutout or seizure is found, replace the parts as a set. Slight damage of some teeth can be corrected by oil stone or the like. 2) Side gear and pinion mate gear Replace if cracks, scoring or other defects are evident on the tooth surface. Replace if thrust washer contact surface is worn or seized. Slight damages of the surface can be corrected by oil stones or equivalent. 3) Bearing Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident. 4) Thrust washer of the side gear and pinion mate gear Replace if seized, flawed, abnormally worn or having other defects. 5) Oil seal Replace if deformed or damaged, and at every disassembling. 6) Differential carrier Replace if the bearing bores are worn or damaged. 7) Differential case Replace if its sliding surfaces are abnormally worn, burned, or cracked. 8) Companion flange Replace if the oil seal lip contact surface shows cracking.
2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid driven gear. Hypoid driven gear backlash: 0.1 0.2 mm (0.004 0.008 in) If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
DI-00099
3. HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE

Using a dial gauge, check the hypoid driven gear back surface runout. Hypoid driven gear back surface runout: 0.05 mm (0.002 in) If the hypoid driven gear runout exceeds 0.05 mm (0.002 in), replace the hypoid driven gear.
1. SIDE GEAR BACKLASH

Using a dial gauge, check the backlash of side gear. (Model without LSD) Side gear backlash: 0.1 0.2 mm (0.004 0.008 in) If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.
DI-00101
4. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION

Inspect the tooth contact between the hypoid driven gear and drive pinion. <Ref. to DI-37, ASSEMBLY, Rear Differential (T-type).>
DI-00315
DI-54

DIFFERENTIALS
5. TOTAL PRELOAD
Using a spring scale, check the total preload. Total preload: Except for GT spec. B 6MT model: 20.7 54.4 N (2.1 5.5 kgf, 4.7 12.2 lb) GT spec. B 6MT model 27.0 54.0 N (2.8 5.5 kgf, 6.1 12.1 lb) If the total preload is not within the specifications, adjust the side retainer shims.
4) If either runout exceeds the limit, move the phase of companion flange and drive pinion 90 each, and find the point where the runout is within the limit. 5) If the runout exceeds the limit even after changing the phase, replace the companion flange and recheck the runout. 6) If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
F: ADJUSTMENT
Adjust the side gear backlash. <Ref. to DI-37, ASSEMBLY, Rear Differential (T-type).>

Adjust hypoid driven gear backlash. <Ref. to DI-37, ASSEMBLY, Rear Differential (T-type).>
DI-00117
6. COMPANION FLANGE
1) If rust or dirt is attached to the companion flange, remove them. 2) Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout. Limit of runout: 0.08 mm (0.003 in)

Adjust the tooth contact between hypoid driven gear and drive pinion gear. <Ref. to DI-37, ASSEMBLY, Rear Differential (T-type).>
4. TOTAL PRELOAD
Adjust the side retainer shim. <Ref. to DI-37, ASSEMBLY, Rear Differential (T-type).>
DI-00360
3) Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.003 in)
DI-00361
DI-55
Rear Differential (VA-type)

DIFFERENTIALS
5. Rear Differential (VA-type)

A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Shift the select lever or gear shift lever to neutral. 4) Release the parking brake. 5) Loosen the wheel nuts. 6) Lift up the vehicle. 7) Remove the wheels. 8) Drain the differential gear oil. <Ref. to DI-26, REPLACEMENT, Differential Gear Oil.> 9) Remove the rear exhaust pipe and muffler. 2.5 L SOHC non-turbo model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> 2.5 L DOHC turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 3.0 L DOHC non-turbo model <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.> 10) Remove the heat shield cover.
13) Loosen the self-lock nuts which hold the rear differential to rear crossmember.
DI-00269
14) Remove the DOJ of rear drive shaft from rear differential.
(A)
(B) DI-00287
(A) Tire lever (B) Bolt
15) Remove the nuts which hold the rear differential front member.
AT-01331
11) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 12) Prepare the transmission jack and band.
DI-00362
16) Support the rear differential with the transmission jack.
DI-00268
DI-00273
17) Remove the rear differential front member. 18) Secure the rear differential using band.
DI-56

DIFFERENTIALS
19) Remove the self-lock nuts which hold the rear differential to rear crossmember. 20) Remove the rear differential stud bolt from rear crossmember bushing. NOTE: When removing the stud bolt, carefully adjust the angle and location of transmission jack and jack stand, if necessary
24) Secure the rear drive shaft to lateral link using wire.
DI-00277
25) Remove the rear differential member plate from rear differential.
(A)
DI-00400
21) Lower the transmission jack stand after removing the rear differential stud bolt from the rear crossmember. Rear drive shaft should not come into contact with the lateral link bolt.
DI-00359
DI-00392
22) Pull out the axle shaft from rear differential. NOTE: If it is difficult to remove the axle shaft from rear differential, remove it using tire lever.
DI-00276
23) Lower the transmission jack.
DI-57

DIFFERENTIALS
B: INSTALLATION
1) Insert the rear differential member plate into the rear differential.
(A)
6) Push the rear differential to insert the axle shaft into rear differential.
DI-00281 DI-00359
7) Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear crossmember bushing properly.
2) Set the rear differential to transmission jack. NOTE: Secure the rear differential to transmission jack using band. 3) Attach the ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR
DI-00393
8) After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.
ST DI-00300
4) Insert the spline shaft until the spline portion comes inside the side oil seal.
DI-00283
9) Tighten a new self-locking nut temporarily to rear crossmember.

ST DI-00289
5) Remove ST from rear differential.
DI-00269
DI-58

DIFFERENTIALS
10) Remove the band from rear differential. Lift up the rear differential until the rear differential is separated from the transmission jack. 11) Install the rear differential front member with a new self-locking nut. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 110 Nm (11.2 kgf-m, 81.1 ft-lb)
T1
16) Install the rear exhaust pipe and muffler. 2.5 L SOHC non-turbo model <Ref. to EX(H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, INSTALLATION, Muffler.> 2.5 L DOHC turbo model <Ref. to EX(H4DOTC)-13, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Muffler.> 3.0 L DOHC non-turbo model <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, INSTALLATION, Muffler.> 17) After installing the rear differential carrier to the vehicle, remove the filler plug, and refill with gear oil up to the lower lip of the plug hole. Oil capacity: 0.8 2 (0.8 US qt, 0.7 Imp qt) VA1-type
(A)
T2
DI-00395
12) Tighten the self-locking nut. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
(B) DI-00528
DI-00269
13) Lower the transmission jack. 14) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.> 15) Install the heat shield cover.
VA2-type
(A) (B) DI-00355
AT-01331
DI-59

DIFFERENTIALS
18) Tighten the filler plug. NOTE: For VA-type, use a new gasket. Tightening torque: VA1-type: 34 Nm (3.5 kgf-m, 25.1 ft-lb) VA2-type: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 19) Hereafter, install in the reverse order of removal.
4) Remove the air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
(A) (B)
C: DISASSEMBLY
1. VA1-TYPE
To detect the real cause of trouble, inspect the following items before disassembling. Tooth contact and backlash between hypoid driven gear and drive pinion Hypoid driven gear runout on its back surface Total preload of drive pinion 1) Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
DI-00561
5) Remove the lock plate RH and LH.
DI-00132 ST DI-00129
2) Remove the oil drain plug and filler plug, and drain the gear oil. 3) Remove the mounting bolts, and remove the rear cover. NOTE: Remove by tapping with a plastic hammer.
6) Remove the side retainer RH and LH with the ST. ST 18630AA010 WRENCH COMPL RETAINER
ST DI-00133
DI-00130
DI-60

DIFFERENTIALS
10) Extract the bearing cone with ST1 and ST2. NOTE: Do not attempt to disassemble the parts unless necessary. Set the puller so that its claws catch the edge of the bearing cone. Store so that the right and left side bearing races and cones are not mixed together. ST1 899524100 PULLER SET ST2 399520105 SEAT
ST1 DI-00134
8) Remove the bearing race from side retainer RH and LH with ST1 and ST2. ST1 499705401 PULLER ASSY ST2 499705404 SEAT
ST2
DI-00137 ST1 (A) ST2 (B) DI-00135
(A) Bearing race (B) Side retainer
9) Remove the oil seal from the side retainer RH and LH using a screwdriver. NOTE: Perform this operation only when changing oil seal.
DI-00068
12) Drive out the pinion shaft lock pin from the hypoid driven gear side. NOTE: The lock pin is staked at the pin hole end on the differential case. Do not drive it out forcibly before removing the stake. ST 899904100 STRAIGHT PIN REMOVER
ST
DI-00136
DI-00237
DI-61

DIFFERENTIALS
13) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers. NOTE: The gears should be marked or kept separated right and left, and front and rear as well as thrust washers.
16) Press the end of drive pinion shaft and extract it together with rear bearing cone, pinion height adjusting washer and washer. NOTE: Hold the drive pinion so as not to drop it. ST 398467700 DRIFT
ST
DI-00238
DI-00073
(A) (B) (C) (D) (E)
Side gear Pinion mate gear Thrust washer Differential case Pinion mate shaft
ST
DI-00074 ST DI-00141
18) Remove the front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
(A)

(A)
(B) DI-00145 (B) DI-00142
(A) Differential carrier (B) Front oil seal
DI-62

DIFFERENTIALS
19) Remove the pilot bearing together with the front bearing cone and spacer using the ST. ST 398467700 DRIFT
ST
2) Remove the oil drain plug and filler plug, and drain the gear oil. 3) Remove the mounting bolts, and remove the rear cover. NOTE: Remove by tapping with a plastic hammer.
(D)
(C)
(B)
(A) DI-00076
(A) (B) (C) (D)
DI-00388
4) Remove the air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
(A) (B)
(A)
(B)
DI-00077 DI-00562
(A) 2 cutout portions along diagonal lines (B) Tap alternately with brass bar.
2. VA2-TYPE
To detect the real cause of trouble, inspect the following items before disassembling. Tooth contact and backlash between hypoid driven gear and drive pinion Total preload of drive pinion 1) Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
5) Remove the lock plate RH and LH.
DI-00364
ST DI-00363
DI-63

DIFFERENTIALS
6) Remove the side retainer RH and LH with the ST. ST 18630AA010 WRENCH COMPL RETAINER
(A)
ST
DI-00368 ST
(A) Side retainer

DI-00365
9) Remove the oil seal from the side retainer RH and LH using a screwdriver. NOTE: Perform this operation only when changing oil seal.
DI-00369 DI-00366
8) Remove the bearing race from side retainer RH and LH with ST and a press. ST 18758AA000 PULLER NOTE: Be sure to turn the bolt of puller manually. Set the puller so that its claws catch the groove of side retainer.
10) Extract the bearing cone with ST1, ST2 and ST3. NOTE: Do not attempt to disassemble the parts unless necessary. Never mix up the RH and LH bearing races and cones. ST1 498077000 REMOVER ST2 399520105 SEAT ST3 899864100 REMOVER
ST
ST ST3 (A) (B)
ST1
DI-00367 ST2
(A) Groove (B) Claw
DI-00370
DI-64

DIFFERENTIALS
DI-00371
ST
DI-00373
ST
16) Remove the front oil seal from differential carrier using screwdriver. 17) Remove the pilot bearing, front bearing cone and spacer.
DI-00372

(A) (D) (C) (B) (A) DI-00374
(A) (B) (C) (D)

(B) DI-00394
(A)
14) Removes the drive pinion shaft.
(B)
DI-00077
(A) 2 cutout portions along diagonal lines (B) Tap alternately with brass bar.
DI-65

DIFFERENTIALS
D: ASSEMBLY
1. VA1-TYPE
NOTE: Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Use new gaskets and O-rings. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Replace the oil seals and O-rings with new parts at every disassembly. Apply differential gear oil to the lips when installing the oil seal. Be careful not to mix up the differential oil seal RH and LH.
(2) Install the front bearing race to the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 498447110 DRIFT (3) Insert the front bearing cone. NOTE: Use new front bearing cone. (4) Measure and record the thickness of pinion height adjusting washer. NOTE: If tooth contact (drive pinion and hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then reuse the used washer. (5) Insert ST1 into the case with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: Use new rear bearing cone. (6) Install the preload adjusting spacer & washer, front bearing cone, ST2, companion flange, and washer & self-locking nut. ST 498447150 DUMMY SHAFT Part No. 32285AA000 Spacer
(A) (B) (C)
DI-00078
1) Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with spacer and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted. (1) Install the rear bearing race into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477702 DRIFT
ST1 (D) ST DI-00466
(A) (B) (C) (D)
Pinion height adjusting washer Preload adjusting spacer Preload adjusting washer Spacer (SUBARU genuine part)
ST2
DI-00149
DI-66

DIFFERENTIALS
(7) Turn the ST1 by hand to smooth the bearing, and tighten the self-locking nut while measuring the initial load or initial torque with a spring scale or torque wrench. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque. NOTE: Use a new self-locking nut. Measure the preload in direction of tangent to the flange. Be careful not to give excessive preload. When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure. ST1 498447150 DUMMY SHAFT ST2 398507704 BLOCK Tightening torque: 191 Nm (19.5 kgf-m, 140.9 ft-lb)
ST1 ST2
Preload adjusting washer Part No. Thickness mm (in) 38336AA000 1.500 (0.0591) 38336AA120 1.513 (0.0596) 38336AA010 1.525 (0.0600) 38336AA130 1.538 (0.0606) 38336AA020 1.550 (0.0610) 38336AA140 1.563 (0.0615) 38336AA030 1.575 (0.0620) 38336AA150 1.588 (0.0625) 38336AA040 1.600 (0.0630) 38336AA160 1.613 (0.0635) 38336AA050 1.625 (0.0640) 38336AA170 1.638 (0.0645) 38336AA060 1.650 (0.0650) 38336AA180 1.663 (0.0655) 38336AA070 1.675 (0.0659) 38336AA190 1.688 (0.0665) 38336AA080 1.700 (0.0669) 38336AA200 1.713 (0.0674) 38336AA090 1.725 (0.0679) 38336AA210 1.738 (0.0684) 38336AA100 1.750 (0.0689) 38336AA220 1.763 (0.0694) 38336AA110 1.775 (0.0699) Preload adjusting spacer Part No. Length mm (in) 32288AA040 52.3 (2.059) 32288AA050 31454AA100 32288AA060 31454AA110 32288AA070 31454AA120 32288AA080 32288AA090 52.5 (2.067) 52.6 (2.071) 52.7 (2.075) 52.8 (2.079) 52.9 (2.083) 53.0 (2.087) 53.1 (2.091) 53.3 (2.098)
DI-00081
DI-00152
DI-00481
DI-67

DIFFERENTIALS
2) Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. (1) Attach ST2. NOTE: At this time, install a provisionally selected or previously used pinion height adjusting washer. ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL CARRIER GAUGE Part No. 32285AA000 Spacer
(B) ST1 RH N ST2
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one. NOTE: Adjust it using 1 3 washers. T = To + N 0.05 mm (0.0020 in)
T To N Memo: Thickness of pinion height adjusting washer mm (in) Thickness of washer temporarily inserted mm (in) Clearance of thickness gauge mm (in)
(A)
LH
DI-00467
N Measured value (A) Pinion height adjusting washer (B) Spacer (SUBARU genuine part)
(Example of calculation) To = 0.15 mm (0.0059 in) N = 0.1 mm (0.0039 in) T = 0.15 mm (0.0059 in) + 0.1 mm (0.0039 in) 0.05 mm (0.0020 in) = 0.2 mm (0.0079 in) Result: Thickness = 0.2 mm (0.0079 in) Therefore use part number 32295AA220.
Pinion height adjusting washer Part No. Thickness mm (in) 32295AA200 0.150 (0.0059) 32295AA210 0.175 (0.0069) 32295AA220 0.200 (0.0079) 32295AA230 0.225 (0.0089) 32295AA240 0.250 (0.0098) 32295AA250 0.275 (0.0108)
(2) Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST2. ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL CARRIER GAUGE
ST2
ST1 ST DI-00084
DI-00085
DI-68

DIFFERENTIALS
(A) (B) (C)
ST
(D)
DI-00156
(A) (B) (C) (D)
DI-00089
8) Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT
ST1
5) Press-fit the front bearing cone into the carrier with ST1, ST2 and the spacer. ST1 399780104 WEIGHT ST2 899580100 INSTALLER Part No. 32285AA000 Spacer
ST2 (A)
ST2 ST1 DI-00468 DI-00090
9) Attach a new self-locking nut and secure the companion flange using ST, then tighten the nut. NOTE: Before installing lock nuts, apply seal material to lock nut threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent ST 498427200 FLANGE WRENCH Tightening torque: 191 Nm (19.5 kgf-m, 140.9 ft-lb)
(A) Spacer (SUBARU genuine part)
6) Insert the spacer, then press-fit the pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
ST2
ST1 DI-00088 ST
DI-00161
DI-69

DIFFERENTIALS
11) Assembling differential case Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into the differential case. NOTE: Apply gear oil on both sides of the washer and on the side gear shaft before installing. Insert the pinion mate shaft into the differential case by aligning the lock pin holes.
DI-00152
DI-00481
DI-00239
(1) Measure the side gear backlash. Side gear backlash: 0.05 0.15 mm (0.002 0.006 in)
DI-00240
(2) Adjust the side gear backlash as specified by selecting side gear thrust washer.
Part No. 803135011 803135012 803135013 803135014 803135015 Side gear thrust washer Thickness mm (in) 0.925 0.950 (0.0364 0.0374) 0.950 0.975 (0.0374 0.0384) 0.975 1.000 (0.0384 0.0394) 1.000 1.025 (0.0394 0.0404) 1.025 1.050 (0.0404 0.0413)
DI-70

DIFFERENTIALS
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces. (4) After inserting the pinion shaft lock pin into differential case, stake the both sides of the hole to prevent pin from falling off. 12) Install the hypoid driven gear to differential case. NOTE: Before installing bolts, apply seal material to bolt threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tighten diagonally. Tightening torque: 62 Nm (6.3 kgf-m, 45.7 ft-lb)
14) Assemble the side retainer. (1) Attach the oil seal to the side retainer RH and LH. ST 498447100 INSTALLER
ST
DI-00166
(2) Attach the bearing race to side retainer RH and LH. ST 398477702 DRIFT CAUTION: Be careful to properly match the RH and LH oil seals, bearing outer races and cones during assembly.
ST
DI-00068
DI-00167
(3) Install the differential assembly into differential carrier in the reverse order of disassembly.
ST
NOTE: Be careful not to hit the teeth against the case.
DI-00095
DI-00134
(4) Push the side retainer RH and LH lightly into the differential carrier to install.
DI-71

DIFFERENTIALS
15) Perform the backlash adjustment between the hypoid driven gear and drive pinion, and preload adjustment of differential side bearing. (1) Turn the drive pinion with ST for better fitting of differential side bearing. ST 498427200 FLANGE WRENCH
(5) Measure the hypoid driven gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. NOTE: If measured value of backlash is not within the specified range, repeat the procedures for pinion driven gear set backlash adjustment and the differential side bearing preload adjustment. Backlash: 0.10 0.15 mm (0.004 0.006 in)
ST
DI-00169
(2) Using the ST, tighten side retainer RH, and then tighten side retainer LH until there is no backlash. ST 18630AA010 WRENCH COMPL RETAINER
DI-00172
ST DI-00133
16) Mark both the differential carrier and side retainer with alignment marks. Remove the side retainer one side at a time. Replace them in the original position after inserting an O-ring and applying gear oil to the threaded portion.
(A)
(3) Back off the side retainer LH by approx. 1.5 teeth, and tighten the side retainer RH by approx. 2 teeth (amount that the side retainer LH is turned back (1.5) + 1/2 teeth). Difference between [amount that the side retainer LH is turned back (approx. 1 and 1/2 teeth)] and [amount that the side retainer RH is tightened (approx. 2 teeth)] gives preload. (4) Temporarily tighten the lock plate. NOTE: Turn over the lock plate to shift the holder by 1/2 tooth.
(B) DI-00173
(A) Alignment mark (B) Side retainer
DI-00132
DI-72

DIFFERENTIALS
17) Tighten the bolt of lock plate to specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.)
(A)
(B)
DI-00132
MT-01401
18) Recheck the hypoid driven gear to pinion backlash. Backlash: 0.10 0.15 mm (0.004 0.006 in)
DI-00172
19) Checking and adjusting the tooth contact of hypoid driven gear (1) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear. (2) When the contact pattern is not correct, readjust. NOTE: Be sure to wipe off the lead-free red dye after the adjustment is completed.
AT-00208
AT-00212
DI-73

DIFFERENTIALS
AT-00209
AT-00211
AT-00212 AT-00213
20) If correct tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash. 21) Install the new gasket and rear cover to the differential carrier, and tighten the bolts to specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
(A)
AT-00210
DI-00189
(A) Rear cover
AT-00213
DI-74

DIFFERENTIALS
22) Install the air breather cap. NOTE: When installing the air breather cap, hit on section (A). Be sure to hit on section (B) to install.
(A) (B)
1) Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with spacer and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted. (1) Install the rear bearing race into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477703 DRIFT 2
ST1 DI-00563
23) Install the oil drain plug and filler plug. Tightening torque: 34 Nm (3.5 kgf-m, 25.1 ft-lb)
2. VA2-TYPE
NOTE: Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Use new gaskets and O-rings. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Replace the oil seal with a new part at every disassembly. Apply differential gear oil to the lips when installing the oil seal. Be careful not to mix up the differential oil seal RH and LH.
ST2 DI-00375
(2) Using the ST, install the front bearing race to the differential carrier. ST 499277200 INSTALLER
ST
DI-00376
(3) Insert the front bearing cone. NOTE: Use new front bearing cone. (4) Measure and record the thickness of pinion height adjusting washer. NOTE: If tooth contact (drive pinion, hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer. (5) Insert the ST1 into carrier with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: Use new rear bearing cone.
DI-00078
DI-75

DIFFERENTIALS
(6) Install the preload adjusting spacer & washer, front bearing cone, spacer, companion flange, and washer & self-locking nut. ST1 18678AA000 DUMMY SHAFT
(A) (B) (C) (D)
DI-00152 ST1 DI-00377
(A) (B) (C) (D)
Pinion height adjusting washer Preload adjusting spacer Preload adjusting washer Spacer
(7) Turn ST1 by hand to seat the bearing, and measure the initial load and initial torque with a spring scale or a torque wrench while tightening the self-locking nut. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque. NOTE: Use a new self-locking nut. Be careful not to give excessive preload. When tightening the self-locking nut, lock companion flange with ST2 as shown in the figure. Measure the preload in direction of tangent to the flange. ST1 18678AA000 DUMMY SHAFT ST2 498427200 FLANGE WRENCH Tightening torque: 191 Nm (19.5 kgf-m, 140.9 ft-lb)
DI-00481
ST2
DI-00398
DI-76

DIFFERENTIALS
Preload adjusting washer Part No. Thickness mm (in) 38336AA430 1.500 (0.0591) 38336AA440 1.513 (0.0596) 38336AA450 1.525 (0.0600) 38336AA460 1.538 (0.0606) 38336AA470 1.550 (0.0610) 38336AA480 1.563 (0.0615) 38336AA490 1.575 (0.0620) 38336AA500 1.588 (0.0625) 38336AA510 1.600 (0.0630) 38336AA520 1.613 (0.0635) 38336AA530 1.625 (0.0640) 38336AA540 1.638 (0.0645) 38336AA550 1.650 (0.0650) 38336AA560 1.663 (0.0655) 38336AA570 1.675 (0.0659) 38336AA580 1.688 (0.0665) 38336AA590 1.700 (0.0669) 38336AA600 1.713 (0.0674) 38336AA610 1.725 (0.0679) 38336AA620 1.738 (0.0684) 38336AA630 1.750 (0.0689) 38336AA640 1.763 (0.0694) 38336AA650 1.775 (0.0699) Preload adjusting spacer Part No. Length mm (in) 31454AA250 51.05 (2.010) 31454AA260 31454AA270 31454AA280 31454AA290 31454AA300 31454AA310 31454AA320 31454AA330 51.25 (2.018) 51.35 (2.022) 51.45 (2.026) 51.55 (2.030) 51.65 (2.033) 51.75 (2.037) 51.85 (2.041) 52.05 (2.049)
2) Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. (1) Attach ST2. ST1 18678AA000 DUMMY SHAFT ST2 18831AA010 DIFFERENTIAL CARRIER GAUGE
ST1 RH N ST2
(A)
LH
DI-00379
N Measured value (A) Pinion height adjusting washer
(2) Install the side retainer LH to the left side of the differential carrier in the reverse direction.
DI-00380
(3) Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST2. ST1 18678AA000 DUMMY SHAFT ST2 18831AA010 DIFFERENTIAL CARRIER GAUGE
ST2
ST1
DI-00381
DI-77

DIFFERENTIALS
(4) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one. NOTE: Adjust it using 1 3 washers. T = To + N 0.05 mm (0.002 in)
T To N Memo: Thickness of pinion height adjusting washer mm (in) Thickness of washer temporarily inserted mm (in) Clearance of thickness gauge mm (in)
(A) (B) (C)
(D)
DI-00382
(Example of calculation) To = 0.15 mm (0.0059 in) N = 0.1 mm (0.0039 in) T = 0.15 mm (0.0059 in) + 0.1 mm (0.0039 in) 0.05 mm (0.0020 in) = 0.2 mm (0.0079 in) Result: Thickness = 0.2 mm (0.0079 in) Therefore use part number 32295AA370.
Pinion height adjusting washer Part No. Thickness mm (in) 32295AA350 0.150 (0.0059) 32295AA360 0.175 (0.0069) 32295AA370 0.200 (0.0079) 32295AA380 0.225 (0.0089) 32295AA390 0.250 (0.0098) 32295AA400 0.275 (0.0108)
(A) (B) (C) (D)
5) Set ST and differential carrier to the press and install the front bearing cone. ST 399780104 WEIGHT
ST
DI-00383
NOTE: Set the carrier to the press until the companion flange is installed. 6) Insert the spacer, then install the pilot bearing.
(A)
(B)
ST DI-00389 DI-00085
(A) Pilot bearing (B) Spacer
DI-78

DIFFERENTIALS
11) Measure the initial torque and initial load. Initial load: 12.7 32.2 N (1.3 3.3 kgf, 2.9 7.2 lb)
ST
DI-00152
DI-00089
8) Press-fit the companion flange with ST. NOTE: Be careful not to damage the bearing. ST 899874100 INSTALLER
ST DI-00481
12) Install the hypoid driven gear to differential case.

DI-00384
9) Apply seal material on the drive pinion shaft thread and new self-locking nut seat. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent 10) Tighten the nut and use the ST to fix the companion flange in place, then tighten. ST 498427200 FLANGE WRENCH Tightening torque: 191 Nm (19.5 kgf-m, 140.9 ft-lb)
NOTE: Set a cushioning such as wooden block, aluminum plate or shop cloth between vise and differential case if the side gear comes into contact with vise. Before installing bolts, apply seal material to bolt threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) Tighten diagonally. Tightening torque: 62 Nm (6.3 kgf-m, 45.7 ft-lb)
ST
DI-00372
DI-00371
DI-79

DIFFERENTIALS
15) Perform the backlash adjustment between the hypoid driven gear and drive pinion, and preload adjustment of differential side bearing. (1) Turn the drive pinion with ST for better fitting of differential side bearing. ST 498427200 FLANGE WRENCH
ST
ST
DI-00095
14) Assemble the side retainer. (1) Attach the new oil seal to the side retainer RH and LH. ST 498447100 INSTALLER
DI-00385
(2) Using the ST, tighten the side retainer LH, and then tighten the side retainer RH until there is no backlash. ST 18630AA010 WRENCH COMPL RETAINER
ST
DI-00166
(2) Attach the bearing race to side retainer RH and LH. ST 398417700 DRIFT CAUTION: Be careful to properly match the RH and LH oil seals, bearing outer races and cones during assembly. (3) Install the differential assembly into differential carrier in the reverse order of disassembly. NOTE: Be careful not to hit the teeth against the case.
ST
DI-00399
(3) Back off the side retainer LH by approx. 1.5 teeth, and tighten the side retainer RH by approx. 2 teeth (amount that the side retainer LH is turned back (1.5) + 1/2 teeth). Difference between [amount that the side retainer LH is turned back (approx. 1 and 1/2 teeth)] and [amount that the side retainer RH is tightened (approx. 2 teeth)] gives preload. (4) Temporarily tighten the lock plate. NOTE: Turn over the lock plate to shift the holder by 0.5 teeth.
DI-00366
(4) Push the side retainer RH and LH lightly into the differential carrier to install.
DI-00364
DI-80

DIFFERENTIALS
(5) Measure the hypoid driven gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. NOTE: If measured value of backlash is not within the specified range, repeat the procedures for pinion driven gear set backlash adjustment and the differential side bearing preload adjustment. Backlash: 0.10 0.15 mm (0.004 0.006 in)
17) Tighten the bolt of lock plate to specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
DI-00364
18) Recheck the hypoid driven gear to pinion backlash. Backlash: 0.10 0.15 mm (0.004 0.006 in)
DI-00172
16) Mark both the differential carrier and side retainer with alignment marks. Remove the side retainer one side at a time. Replace them in the original position after inserting an O-ring and applying differential gear oil to the threaded portion.
(A)
DI-00172
(B)
19) Checking and adjusting the tooth contact of hypoid driven gear (1) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear. (2) When the contact pattern is not correct, readjust. NOTE: Be sure to wipe off the lead-free red dye completely after the adjustment is completed.
DI-00386
(A) Alignment mark (B) Side retainer
DI-81

DIFFERENTIALS
Correct tooth contact Check item: Tooth contact pattern is slightly shifted towards the toe side under no-load rotation. (When driving, it moves towards the heel side.)
(A)
(B) AT-00209 MT-01401
AT-00213
AT-00208
AT-00210
AT-00212
AT-00213
DI-82

DIFFERENTIALS
22) Install the air breather cap. NOTE: When installing the air breather cap, hit on section (A). Be sure to hit on section (B) to install.
(A) (B)
AT-00211
DI-00564
23) Tighten the oil drain plug and filler plug. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
E: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage or other defects. Repair or replace the defective parts as necessary. 1) Hypoid driven gear and drive pinion If there is evidently an abnormal tooth contact, find out the cause and adjust until the teeth contact correctly. Replace the gear if there is an excessive worn or an incapable adjustment. If crack, cutout or seizure is found, replace the parts as a set. Slight damage of some teeth can be corrected by oil stone or the like. 2) Side gear and pinion mate gear Replace if cracks, scoring or other defects are evident on the tooth surface. Replace if thrust washer contact surface is worn or seized. Slight damages of the surface can be corrected by oil stones or equivalent. 3) Bearing Replace if seizure, peeling, wear, rust, dragging during rotation, noise or other defect is evident. 4) Thrust washer of the side gear and pinion mate gear Replace if seized, flawed, abnormally worn or having other defects. 5) Oil seal Replace if deformed or damaged, and at every disassembling. 6) Differential carrier Replace if the bearing bores are worn or damaged. 7) Differential case Replace if its sliding surfaces are abnormally worn, burned, or cracked. 8) Companion flange Replace if the oil seal lip contact surface shows cracking.
AT-00212
20) If correct tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash. 21) Install the new gasket and rear cover to the differential carrier, and tighten the bolts to specified torque. Tightening torque: 34 Nm (3.5 kgf-m, 25.1 ft-lb)
DI-00387
DI-83

DIFFERENTIALS

Using a dial gauge, check the backlash of side gear. (VA1-type only) Side gear backlash: 0.05 0.15 mm (0.002 0.006 in) If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.
4. COMPANION FLANGE
1) If rust or dirt is attached to the companion flange, remove them. 2) Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout. Limit of runout: 0.08 mm (0.003 in)
DI-00240

Using a dial gauge, check the backlash of hypoid driven gear. Hypoid driven gear backlash: 0.10 0.15 mm (0.004 0.006 in) If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
DI-00360
3) Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.003 in)
DI-00361
DI-00099

Inspect the tooth contact between the hypoid driven gear and drive pinion. <Ref. to DI-66, ASSEMBLY, Rear Differential (VA-type).>
4) If either runout exceeds the limit, move the phase of companion flange and drive pinion 90 each, and find the point where the runout is within the limit. 5) If the runout exceeds the limit even after changing the phase, replace the companion flange and recheck the runout. 6) If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
DI-84

DIFFERENTIALS
F: ADJUSTMENT
Adjust the side gear backlash. (VA1-type) <Ref. to DI-66, ASSEMBLY, Rear Differential (VA-type).>

Adjust hypoid driven gear backlash. <Ref. to DI-66, ASSEMBLY, Rear Differential (VA-type).>

Adjust the tooth contact between hypoid driven gear and drive pinion gear. <Ref. to DI-66, ASSEMBLY, Rear Differential (VA-type).>
DI-85
Rear Differential Front Oil Seal

DIFFERENTIALS
6. Rear Differential Front Oil Seal

A: INSPECTION
Make sure that there is no leakage from front oil seal portion. If there is any leakage replace the oil seal and inspect the propeller shaft.
VA2-type
(A)
B: REPLACEMENT
1) Disconnect the ground cable from battery. 2) Shift the select lever or gear shift lever to neutral. 3) Release the parking brake. 4) Lift up the vehicle. 5) Remove the oil drain plug, and drain gear oil. T-type
(A) (B)
(B) DI-00357
6) Install the oil drain plug. NOTE: Apply liquid gasket to the drain plug for the Ttype (except for GT spec. B 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Use a new gasket for the VA-type and T-type (GT spec. B 6MT model).
DI-00356
VA1-type
(A) (B)
DI-00505
Tightening torque: T-type (except for GT spec.B 6MT model): 49 Nm (5.0 kgf-m, 36.1 ft-lb) T-type (GT spec. B 6MT model): 60 Nm (6.1 kgf-m, 44.3 ft-lb) VA1-type: 34 Nm (3.5 kgf-m, 25.1 ft-lb) VA2-type: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 7) Remove the rear exhaust pipe and muffler. 2.5 L SOHC non-turbo model <Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muffler.> 2.5 L DOHC turbo model <Ref. to EX(H4DOTC)-12, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, REMOVAL, Muffler.> 3.0 L DOHC non-turbo model <Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.>
DI-86
Rear Differential Front Oil Seal

DIFFERENTIALS
13) Install a new oil seal using ST. NOTE: Apply the differential gear oil to the oil seal lips. ST 498447120 INSTALLER
ST
AT-01331
9) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.> 10) Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
ST
DI-00292
14) Install the companion flange. NOTE: Use a plastic hammer to install companion flange. 15) Tighten the self-locking nut within the specified torque range so that the rotating resistance of companion flange becomes the same as that of before oil seal replacement. ST 498427200 FLANGE WRENCH NOTE: Use a new self-locking nut. Before installing the self-locking nut, apply seal material to self-locking nut threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: T-type: 181.5 Nm (18.5 kgf-m, 133.9 ft-lb) VA-type: 191 Nm (19.5 kgf-m, 140.9 ft-lb)
ST
DI-00194
11) Remove the companion flange using ST. ST 399703600 PULLER ASSY
ST
DI-00196
12) Remove the oil seal using ST or screwdriver. ST 398527700 PULLER ASSY
DI-00194
ST
DI-00197
16) Hereafter, reassemble in the reverse order of disassembly. 17) After installing, fill with differential gear oil up to the bottom of the filler plug hole. <Ref. to DI-26, Differential Gear Oil.>
DI-87
Rear Differential Side Oil Seal

DIFFERENTIALS
7. Rear Differential Side Oil Seal

A: INSPECTION
Make sure that there is no leakage from side oil seal. If there is any leakage, replace the oil seal.
B: REPLACEMENT
1) Remove the rear differential. <Ref. to DI-30, REMOVAL, Rear Differential (T-type).> <Ref. to DI-56, REMOVAL, Rear Differential (VA-type).> 2) Remove the rear differential side oil seal using a screwdriver or ST wrapped with vinyl tape to prevent the side retainer from scratches. 3) Using the ST, install the oil seal to the side retainer. T-type and VA2-type ST 398437700 DRIFT
ST
DI-00209
VA1-type ST 498447100
INSTALLER
ST
DI-00221
4) Install the rear differential. <Ref. to DI-32, INSTALLATION, Rear Differential (T-type).> <Ref. to DI-58, INSTALLATION, Rear Differential (VAtype).>
DI-88
Rear Differential Front Member

DIFFERENTIALS
8. Rear Differential Front Member

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Lift up the vehicle. 3) Support the rear differential using transmission jack, and then remove the rear differential front member.
(A)
DI-00293
(A) Rear differential front member
B: INSTALLATION
Using new self-locking nuts, install the rear differential front member. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb) T2: 110 Nm (11.2 kgf-m, 81.1 ft-lb)
T2
T1 DI-00294
C: INSPECTION
1) Check the rear differential front member for damage, bend and corrosion. If damage, bend or corrosion is excessive, replace the rear differential front member. 2) Check the bushings of rear differential member for cracking, hardening and damage. If cracking, hardening or damage is excessive, replace rear differential front member.
DI-89

DIFFERENTIALS

A: INSPECTION
Symptom or trouble 1. Oil leakage Possible cause (1) Worn, scratched, or incorrectly seated front or side oil seal. Scored, battered or excessively worn sliding surface of companion flange. (2) Clogged or damaged air breather. (3) Loose bolts on side retainer, or incorrectly fitted O-ring. (4) Loose rear cover attaching bolts or damaged gasket. (5) Loose oil filler or oil drain plug. (6) Wear, damage or incorrect fitting of side retainer or oil seal. (1) Insufficient backlash for hypoid gear. (2) Excessive preload for side, rear or front bearing. (3) Insufficient or improper oil used. Remedy Repair or replace.
Clean, repair or replace. Tighten the bolts to specified torque. Replace the O-ring. Tighten the bolts to specified torque. Replace gasket and apply liquid gasket. Retighten and apply liquid gasket. Repair or replace. Readjust or replace. Readjust or replace. Add specified oil to the specified level.
2. Seizure NOTE: Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired or replaced as required. 3. Damage NOTE: Damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired or replaced as required.
(1) Improper backlash for hypoid gear. (2) Insufficient or excessive preload for side, rear or front bearing. (3) Excessive backlash for differential gear. (4) Loose bolts and nuts such as hypoid driven gear bolt (5) Damage due to overloading. (1) Excessive backlash for hypoid gear. (2) Improper tooth contact of the hypoid gear (3) Excessive backlash for differential gear. (4) Insufficient preload for front or rear bearing. (5) Loose drive pinion nut. (6) Loose bolts and nuts such as side retainer attachment bolt. (1) Damaged differential gear.
Replace. Readjust or replace. Replace gear or thrust washer. (For Ttype (except for GT spec. B 6MT model), replace the differential case assembly.) Retighten. Replace. Readjust. Readjust. (Drive pinion adjustment and backlash adjustment) Replace gear or thrust washer. (For Ttype (except for GT spec. B 6MT model), replace the differential case assembly.) Readjust. Tighten to the specified torque. Tighten to the specified torque. Replace. (For T-type (except for GT spec. B 6MT model), replace the differential case assembly.) Replace. Replace. Replace.
4. Noises when starting or shifting gears NOTE: Noises may be caused by differential assembly, universal joint, wheel bearing, etc. Find out what is actually making noise before disassembling.
5. Noises when cornering
(2) Excessive wear or damage of thrust washer. (3) Broken pinion mate shaft. (4) Seized or damaged side bearing.
DI-90

DIFFERENTIALS
Symptom or trouble 6. Gear Noise NOTE: Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising, and jacking-up all four wheels. Perform these inspections according to the condition of trouble. When listening to noises, shift gears into four wheel drive and fourth speed position, trying to pick up only differential noise. Possible cause (1) Improper tooth contact of hypoid gear. (2) Improper backlash of the hypoid gear. (3) Scored or chipped teeth of hypoid gear. (4) Seized hypoid gear. (5) Improper preload for front or rear bearings. (6) Seized, cut-away or chipped front or rear bearing. (7) Seized, cut-away or chipped side bearing. (8) Vibrating differential gear. Remedy Readjust or replace hypoid gear set. Readjust. Replace hypoid gear set. Replace hypoid gear set. Readjust. Replace. Replace. Replace. (For T-type (except for GT spec. B 6MT model), replace the differential case assembly.)
DI-91

DIFFERENTIALS
DI-92
General Description
TRANSFER CASE
A: NOTE
For general description, refer to the 4AT, 5AT, 5MT or 6MT section. 4AT model: <Ref. to 4AT-2, General Description.> 5AT model: <Ref. to 5AT-2, General Description.> 5MT model: <Ref. to 5MT-2, General Description.> 6MT model: <Ref. to 6MT-2, General Description.>
TC-2

TRANSFER CASE
2. Transfer Case and Extension Case Assembly

A: NOTE
For removal, installation and inspection, refer to the 5MT section. <Ref. to 5MT-38, Transfer Case and Extension Case Assembly.>
TC-3
Transfer Clutch
TRANSFER CASE
3. Transfer Clutch
A: NOTE
For removal, installation and inspection, refer to the 4AT or 5AT section. 4AT model: <Ref. to 4AT-70, Transfer Clutch.> 5AT model: <Ref. to 5AT-70, Transfer Clutch.>
TC-4
Extension Case
TRANSFER CASE
4. Extension Case
A: NOTE
For removal, installation and inspection, refer to the 4AT, 5AT or 6MT section. 4AT model: <Ref. to 4AT-68, Extension Case.> 5AT model: <Ref. to 5AT-68, Extension Case.> 6MT model: <Ref. to 6MT-43, Extension Case.>
TC-5
Oil Seal
TRANSFER CASE
5. Oil Seal
A: NOTE
For replacement and inspection, refer to the 4AT, 5AT, 5MT or 6MT section. 4AT model: <Ref. to 4AT-44, Extension Case Oil Seal.> <Ref. to 4AT-45, Differential Side Retainer Oil Seal.> 5AT model: <Ref. to 5AT-49, Extension Case Oil Seal.> <Ref. to 5AT-50, Differential Side Retainer Oil Seal.> 5MT model: <Ref. to 5MT-33, Oil Seal.> <Ref. to 5MT-34, Differential Side Retainer Oil Seal.> 6MT model: <Ref. to 6MT-28, Oil Seal.> <Ref. to 6MT-29, Differential Side Retainer Oil Seal.>
TC-6
Transfer Drive Gear

TRANSFER CASE
6. Transfer Drive Gear

A: NOTE
For removal, installation and inspection, refer to the 5MT or 6MT section. 5MT model: <Ref. to 5MT-42, Transfer Drive Gear.> 6MT model: <Ref. to 6MT-53, Transfer Drive Gear.>
TC-7

TRANSFER CASE
7. Transfer Driven Gear

A: NOTE
For removal, installation and inspection, refer to the 5MT or 6MT section. 5MT model: <Ref. to 5MT-44, Transfer Driven Gear.> 6MT model: <Ref. to 6MT-55, Transfer Driven Gear.>
TC-8

TRANSFER CASE
8. Reduction Drive Gear

A: NOTE
For removal, installation and inspection, refer to the 4AT section. <Ref. to 4AT-77, Reduction Drive Gear.>
TC-9

TRANSFER CASE
9. Center Differential Carrier

A: NOTE
For removal, installation and inspection, refer to the 5AT section. <Ref. to 5AT-77, Center Differential Carrier.>
TC-10

TRANSFER CASE

A: NOTE
For removal, installation and inspection, refer to the 4AT or 5AT section. 4AT model: <Ref. to 4AT-75, Reduction Driven Gear.> 5AT model: <Ref. to 5AT-74, Reduction Driven Gear.>
TC-11
Center Differential
TRANSFER CASE
A: NOTE
For removal, installation and inspection, refer to the 5MT or 6MT section. 5MT model: <Ref. to 5MT-46, Center Differential.> 6MT model: <Ref. to 6MT-57, Center Differential.>
TC-12

TRANSFER CASE
12.Transfer Clutch Pressure Test

A: NOTE
For inspection, refer to 4AT or 5AT section. 4AT model: <Ref. to 4AT-34, Transfer Clutch Pressure Test.> 5AT model: <Ref. to 5AT-37, Transfer Clutch Pressure Test.>
TC-13

TRANSFER CASE
TC-14
General Description
DRIVE SHAFT SYSTEM
A: SPECIFICATION
1. PROPELLER SHAFT
Model Propeller shaft type Propeller shaft length: L Front propeller shaft Joint-to-joint length: L1 Rear propeller shaft Joint-to-Joint length: L2 Outer diameter of tube: mm (in) mm (in) mm (in) D1 mm (in) D2 1,483 (58.39) 735 (28.9) 1,423 (56.02) 5MT 6MT EDJ 1,423 (56.02) 1,310 (51.57) 562 (22.1) 4AT 5AT
675 (26.6) 675 (26.6) 748 (29.4) 63.5 (2.50) 57.5 (2.26)
L1
L2
D1
D2
DS-00226
DS-2
General Description
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY

Model Turbo 5MT, 6MT Other than above Type of drive shaft EBJ + PTJ EBJ + PTJ Axle diameterI D mm (in) 26 (1.0) 26 (1.0) Axle length L mm (in) 332.5 (13.09) 349.6 (13.76)
(B)
(A)
DS-00227
(A)
Axle diameter
(B)
Axle length
3. REAR DRIVE SHAFT ASSEMBLY

Model 2.5 i AT 6MT Other than above Type of drive shaft BJ + DOJ EBJ + DOJ EBJ + DOJ Axle diameterI D mm (in) 22 (0.87) 22 (0.87) 22 (0.87) Axle length L mm (in) 382 (15.04) 331.8 (13.06) 375.1 (14.77)
(B)
(A)
DS-00228
(A)
Axle diameter
(B)
Axle length
DS-3
General Description
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
(1)
(2)
(2) T1
(3)
T2
(4)
T1
(5) T1
DS-00229
(1) (2) (3)
Propeller shaft Bushing Rear differential (VA1-type)
(4) (5)
Rear differential (T-type) Rear differential (VA2-type)
DS-4
General Description
DRIVE SHAFT SYSTEM
2. FRONT AXLE
(1) (2) (3) (4) (5) (6) (8)
(10) (9) (7)
T2 (14) (11) (12) (13) DS-00232 T1
(1) (2) (3) (4) (5) (6)
Circlip Baffle plate Outer race (PTJ) Snap ring Trunnion Snap ring
(7) (8) (9) (10) (11) (12)
Boot band Boot (PTJ) Boot (EBJ) EBJ shaft ASSY Housing Hub bolt
(13) (14)
Front hub unit bearing Axle nut
Tightening torque:Nm (kgf-m, ft-lb) T1: 220 (22.4, 162) T2: 65 (6.6, 47.9)
DS-5
General Description
DRIVE SHAFT SYSTEM
3. REAR AXLE
(1) (2) (3) (5) (6) (7) (8) (8) (10)
(4) (9) (8) (11)
(13)
(12)
(14) T2 T1
DS-00233
(1) (2) (3) (4) (5) (6) (7)
Baffle plate (DOJ) Outer race (DOJ) Snap ring Inner race Ball Cage Snap ring
(8) (9) (10) (11)
Boot band Boot (DOJ) Boot (BJ) BJ shaft ASSY (2.5 i AT model) EBJ shaft ASSY (Except for 2.5 i AT model) Rear hub unit bearing
(13) (14)
Hub bolt Axle nut
Tightening torque:Nm (kgf-m, ft-lb) T1: 65 (6.6, 47.9) T2: 240 (24.5, 177)
(12)
DS-6
General Description
DRIVE SHAFT SYSTEM
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Apply grease onto sliding or revolving surfaces before installation. Before installing snap rings, apply sufficient amount of grease to avoid damage and deformation. Before securing a part on a vise, place cushioning materials such as wood blocks, aluminum plates, or waste cloth between the part and the vise.
DS-7
General Description
DRIVE SHAFT SYSTEM
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
(A)
TOOL NUMBER 925091000
DESCRIPTION BAND TIGHTENING TOOL
REMARKS Used for tightening the boot band. (A) Jig for the band (B) Ratchet wrench
(B)
ST-925091000
926470000
AXLE SHAFT PULLER
Used for removing the axle shaft. Used together with the AXLE SHAFT PULLER PLATE (28099PA110).
ST-926470000
18675AA000
ST18675AA000
927080000
HUB STAND
Used for assembling hub bolt in hub.
ST-927080000
DS-8
General Description
DRIVE SHAFT SYSTEM
ILLUSTRATION TOOL NUMBER 28099PA110 DESCRIPTION AXLE SHAFT PULLER PLATE REMARKS Exchange with the plate of the AXLE SHAFT PULLER (926470000) to use.
ST28099PA110
28099PA090
OIL SEAL PROTECTOR
Used for installing the rear drive shaft to the rear differential. For protecting the oil seal.
ST28099PA090
28399SA010
OIL SEAL PROTECTOR
Used for installing front drive shaft into front differential. For protecting the oil seal.
ST28399SA010
28399AG000
HUB STAND
Used for extracting hub bolt.
ST28399AG000
2. GENERAL TOOL
TOOL NAME Puller Dial gauge Extension cap Bar REMARKS Used for removing the ball joint from knuckle arm. Used for inspecting the propeller shaft run-out. Used for preventing leakage of gear oil or ATF. Used for extracting drive shaft.
DS-9
Propeller Shaft
DRIVE SHAFT SYSTEM
2. Propeller Shaft
A: REMOVAL
NOTE: Before removing propeller shaft, wrap metal parts with a cloth or rubber material. In case of a EDJ type, wrap the metal parts at the rubber boot of EDJ with a cloth or rubber material before removing propeller shaft, as shown in the figure. The rubber boot may be damaged due to interference with adjacent metal parts while bending the EDJ during removal.
8) Make alignment marks on the flange yoke and rear differential before removal.
(A)
DS-00028
(A) Alignment mark
9) Remove the three bolts holding the propeller shaft to the rear differential. 10) Remove the remaining bolt. 11) Remove the two bolts which hold center bearing to vehicle body.
DS-00239
1) Disconnect the ground cable from the battery. 2) Shift the select lever or gear shift lever to neutral. 3) Release the parking brake. 4) Lift up the vehicle. 5) Remove the center exhaust pipe. 6) Remove the rear exhaust pipe and muffler. 7) Remove the heat shield cover.
DS-00141
12) Remove the propeller shaft from transmission. CAUTION: Be careful not to damage oil seals and frictional surface of the sleeve yoke. Cover the center exhaust pipe with a cloth to keep off any ATF or oil spilled from transmission when removing propeller shaft. NOTE: Use a container to catch ATF or oil flowing from propeller shaft.
(A)
DS-00230
(A) Heat shield cover
DS-00030
DS-10
Propeller Shaft
DRIVE SHAFT SYSTEM
13) Install an extension cap to the transmission. NOTE: If extension cap is not available, place vinyl bag over opening and fasten with string to prevent gear oil or ATF from leaking.
B: INSTALLATION
1) Insert the sleeve yoke into the transmission and attach center bearing to body. Tightening torque: 52 Nm (5.3 kgf-m, 38.3 ft-lb)
(A)
DS-00031 DS-00141
(A) Extension cap
2) Align the alignment marks and connect the flange yoke and rear differential. Tightening torque: 31 Nm (3.2 kgf-m, 23.1 ft-lb)
(A)
DS-00028
(A) Alignment mark
3) Install the heat shield cover. 4) Install the center exhaust pipe. 5) Install the rear exhaust pipe and muffler. 6) Lower the vehicle. 7) Connect the ground cable to battery.
DS-11
Propeller Shaft
DRIVE SHAFT SYSTEM
C: INSPECTION
NOTE: Do not disassemble propeller shaft. Check the following and replace if necessary. Tube surface for dents of cracks Splines for deformation or abnormal wear Unsmooth joint operation or abnormal noise Center bearing for free play, noise or nonsmooth operation. Oil seals for abnormal wear or damage Damaged center bearing Check the following points with propeller shaft installed in vehicle.
3. RUNOUT OF PROPELLER SHAFT

1) Remove the center exhaust pipe. 2) Remove the rear exhaust pipe and muffler. 3) Remove the heat shield cover. 4) Set the dial gauge with its indicator stem at the center of the propeller shaft tube. 5) Turn the propeller shaft slowly by hands to check for runout of the propeller shaft. Runout: Service limit 0.6 mm (0.024 in)
1. JOINTS AND CONNECTIONS

1) Remove the center exhaust pipe. 2) Remove the heat shield cover. 3) Check for any looseness of the yoke flange mounting bolts which connect to the rear differential and center bearing bracket mounting bolts.
(A)
(B)
2. SPLINES AND BEARING

1) Remove the center exhaust pipe. 2) Remove the rear exhaust pipe and muffler. 3) Remove the heat shield cover. 4) Turn the propeller shaft by hand to see if abnormal free play exists at splines. Also move yokes to see if abnormal free play exists at spiders and bearings.
(A) Propeller shaft (B) Dial gauge
DS-00036
4. CENTER BEARING FREE PLAY

1) Remove the front and center exhaust pipes. 2) Remove the rear exhaust pipe and muffler. 3) Remove the heat shield cover. 4) Move the propeller shaft near the center bearing up, down, left, right by hand, to check for any abnormal free play of the bearings.
DS-00035
DS-00037
DS-12
Front Axle
DRIVE SHAFT SYSTEM
3. Front Axle
A: REMOVAL
1) Disconnect the ground cable from battery. 2) Lift up the vehicle, and remove the front wheels. 3) Lift the crimped section of axle nut.
8) Remove the cotter pin and castle nut securing the tie-rod end to the housing knuckle arm.
(A)
(B)
(C)
DS-00042
DS-00038
(A) Cotter pin (B) Castle nut (C) Tie-rod
4) Remove the axle nut using a socket wrench while depressing the brake pedal. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Remove the stabilizer link.
9) Using a puller, remove the tie-rod ball joint from knuckle arm.
DS-00043
DS-00262
CAUTION: When removing tie-rod, do not hit the tie-rod end with hammer. 10) Remove the ABS wheel speed sensor assembly and harness.
6) Remove the disc brake caliper from the housing, and suspend it from strut using a wire. 7) Remove the disc rotor from the hub. NOTE: If it is difficult to remove the disc rotor from the hub, drive the 8 mm bolt into the threaded end of rotor, and then remove the rotor.
DS-00249
DS-00041
DS-13
Front Axle
DRIVE SHAFT SYSTEM
11) Remove the bolts which secure the sensor harness to the strut.
B: INSTALLATION
1) Align the alignment mark on the camber adjusting bolt head, and tighten the housing and strut using a new self-locking nut. Tightening torque: 155 Nm (15.8 kgf-m, 114.3 ft-lb) 2) Install the front drive shaft. <Ref. to DS-22, INSTALLATION, Front Drive Shaft.> 3) Install the front arm ball joint to the housing.
DS-00144
12) Remove the front arm ball joint from the housing.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 4) Install the ABS sensor harness to the strut. 5) Install the ABS wheel speed sensor on the housing. Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb) 6) Install the disc rotor to hub. 7) Install the disc brake caliper on the housing. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 8) Install the stabilizer link. 9) Connect the tie-rod end ball joint to the knuckle arm with a castle nut. Tightening torque: 27.0 Nm (2.75 kgf-m, 19.9 ft-lb) CAUTION: When connecting the tie-rod, do not hit the cap at bottom of tie-rod end with a hammer. 10) Tighten the castle nut to specified torque and tighten further within 60 until the pin hole is aligned with the slot in nut. Bend the cotter pin to lock.
(A)
DS-00045
13) Remove the front drive shaft from the transmission. 14) Remove the front drive shaft assembly from the hub. If it is hard to remove, use the ST. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE
ST1 (B)
ST2 DS-00145
15) After scribing an alignment mark on camber adjusting bolt head, remove the bolts which connect the housing and strut, and disconnect the housing from strut.
(C)
DS-00042
(A) Cotter pin (B) Castle nut (C) Tie-rod
DS-00046
DS-14
Front Axle
DRIVE SHAFT SYSTEM
11) While depressing the brake pedal, tighten a new axle nut to the specified torque and lock it securely. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft-lb) CAUTION: Install the wheel after installation of axle nut. Failure to follow this rule may damage the wheel bearing. Be sure to tighten the axle nut to specified torque. Do not overtighten it as this may damage the wheel bearing. 12) After tightening the axle nut, lock it securely.
C: DISASSEMBLY
1) Remove the four bolts from the housing, and remove the front hub unit bearing and disc cover.
(A)
DS-00231
(A) Housing
CAUTION: Do not get closer the tool which charged magnetism to magnetic encoder. Be careful not to damage the magnetic encoder.
(2) DS-00048 (1)
13) Install the wheel and tighten the wheel nuts to specified torque. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb)
DS-00250
(1) Magnetic encoder (2) Front hub unit bearing
2) Disassemble the front hub unit bearing. <Ref. to DS-18, DISASSEMBLY, Front Hub Unit Bearing.>
DS-15
Front Axle
DRIVE SHAFT SYSTEM
D: ASSEMBLY
1) Assemble the front hub unit bearing. <Ref. to DS-18, ASSEMBLY, Front Hub Unit Bearing.> 2) Place the disc cover between housing and front hub unit, and tighten the four bolts. Tightening torque: 65 Nm (6.6 kgf-m, 47.9 ft-lb)
E: INSPECTION
1) Moving the front tire up and down by hand, check there is no backlash in bearing, and check the wheel rotates smoothly.
(A)
DS-00061
DS-00231
2) Inspect the lean of axis direction using a dial gauge. Replace the bearing if the load range exceeds the limitation. Service limit: Maximum: 0.05 mm (0.0020 in)
(A) Housing
(2) (1) DS-00062
DS-00250
DS-16
Front Hub Unit Bearing

DRIVE SHAFT SYSTEM
4. Front Hub Unit Bearing

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Lift up the vehicle, and remove the front wheels. 3) Lift the crimped section of axle nut.
(2) (1)
DS-00250 DS-00038
4) Remove the axle nut using a socket wrench while depressing the brake pedal. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Remove the disc brake caliper from the housing, and suspend it from strut using a wire. 6) Remove the disc rotor from the hub. NOTE: If it is difficult to remove the disc rotor from the hub, drive the 8 mm bolt into the threaded end of rotor, and then remove the rotor.
8) Remove the front hub unit bearing. If it is hard to remove, use the ST. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE
ST1
ST2 DS-00145
DS-00041
7) Remove the four bolts from the housing.
(A)
DS-00231
(A) Housing
DS-17
Front Hub Unit Bearing

DRIVE SHAFT SYSTEM
B: INSTALLATION
1) Place the disc cover between housing and front hub unit, and tighten the four bolts. Tightening torque: 65 Nm (6.6 kgf-m, 47.9 ft-lb)
C: DISASSEMBLY
Using the ST and a hydraulic press, push out the hub bolts. ST 28399AG000 HUB STAND CAUTION: Be careful not to hammer the hub bolts. This may deform the hub. Do not reuse the hub bolt.
(A)
NOTE: Since the hub unit bearing can not be disassembled, only hub bolts can be removed.
(1)
DS-00231
(A) Housing
2) Install the front drive shaft. <Ref. to DS-22, INSTALLATION, Front Drive Shaft.> 3) Tighten the axle nut temporarily. 4) Install the disc rotor to hub. 5) Install the disc brake caliper on the housing. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 6) While depressing the brake pedal, tighten a new axle nut to the specified torque and lock it securely. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft-lb) CAUTION: Install the wheel after installation of axle nut. Failure to follow this rule may damage the wheel bearing. Be sure to tighten the axle nut to specified torque. Do not overtighten it as this may damage the wheel bearing. 7) After tightening the axle nut, lock it securely.
ST
DS-00252
(1) Front hub unit bearing
D: ASSEMBLY
1) Attach the hub to the ST securely. ST 927080000 HUB STAND
(1)
ST
DS-00253
(1) Front hub unit bearing
2) Using a press, press the new hub bolts until their seating surfaces contact the hub. NOTE: Use the 12 mm (0.47 in) dia. holes in the HUB STAND to prevent bolts from tilting.
E: INSPECTION
DS-00048
Refer to Front Axle for inspection procedures. <Ref. to DS-16, INSPECTION, Front Axle.> CAUTION: If there is any fault in the bearing, replace hub unit bearing.
DS-18
Rear Hub Unit Bearing

DRIVE SHAFT SYSTEM
5. Rear Hub Unit Bearing

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Lift up the vehicle, then remove the rear wheels. 3) Lift the crimped section of axle nut.
9) Remove the four bolts from rear arm.
DS-00149
10) Remove the hub unit bearing. CAUTION: Be careful not to damage the magnetic encoder. Do not get closer the tool which charged magnetism to magnetic encoder.
(2) (1)
DS-00038
4) While applying the parking brake, remove the axle nut using a socket wrench. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Release the parking brake. 6) Remove the rear ABS wheel speed sensor.
DS-00251
(1) Magnetic encoder (2) Rear hub unit bearing
DS-00147
7) Remove the disc brake caliper from back plate, and suspend it from the stabilizer using a wire.
DS-00150
NOTE: If it is hard to remove, use the ST. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE
DS-00148
8) Remove the disc rotor from the hub. NOTE: Mark the mating surface of hub and disc rotor before removing the disc rotor to avoid confusing when installing. If it is difficult to remove the disc rotor from the hub, drive the 8 mm bolt into the threaded end of rotor, and then remove the rotor.
ST1
ST2
DS-00122
DS-19

DRIVE SHAFT SYSTEM
B: INSTALLATION
1) Aligning the hub unit bearing to the mounting hole of the back plate, install the hub unit assembly and back plate. Tighten the axle nut temporarily. CAUTION: Be careful not to damage the magnetic encoder. Do not get closer the tool which charged magnetism to magnetic encoder.
(2) (1)
8) Install the rear ABS wheel speed sensor and brake cable bracket.
DS-00147
9) Adjust the parking brake lever stroke by turning the adjuster. <Ref. to PB-4, ADJUSTMENT, Parking Brake Lever.> 10) While applying the parking brake and depressing the brake pedal, tighten a new axle nut to the specified torque and lock it securely.
DS-00251
Tightening torque: 240 Nm (24.5 kgf-m, 177 ft-lb) CAUTION: Install the wheel after installation of axle nut. Failure to follow this rule may damage the wheel bearing. Be sure to tighten the axle nut to specified torque. Do not overtighten it as this may damage the wheel bearing. 11) After tightening the axle nut, lock it securely.
2) Tighten the four bolts. Tightening torque: 65 Nm (6.6 kgf-m, 47.9 ft-lb)
DS-00149
3) Remove the axle nut. 4) Draw the rear drive shaft into specified position. 5) Tighten the new axle nut temporarily. 6) Install the disc rotor to hub. 7) Install the disc brake caliper on the back plate. Tightening torque: 66 Nm (6.7 kgf-m, 48.7 ft-lb)
DS-00048
DS-00152
DS-20

DRIVE SHAFT SYSTEM
C: DISASSEMBLY
Using the ST and a hydraulic press, push out the hub bolts. ST 28399AG000 HUB STAND CAUTION: Be careful not to hammer the hub bolts. This may deform the hub. Do not reuse the hub bolt. NOTE: Since the hub unit bearing can not be disassembled, only hub bolts can be removed.
E: INSPECTION
1) Moving the rear tire up and down by hand, check there is no backlash in bearing, and check the wheel rotates smoothly.
DS-00183
(1) ST
2) Inspect the lean of axis direction using a dial gauge. Replace the hub bearing if the play exceeds the limit value. Service limit: Maximum: 0.05 mm (0.0020 in)
DS-00254
(1) Rear hub unit bearing
D: ASSEMBLY
1) Attach the hub to the ST securely. ST 927080000 HUB STAND
(1) DS-00062
ST DS-00255
(1) Rear hub unit bearing
2) Using a press, press the new hub bolts until their seating surfaces contact the hub. NOTE: Use the 12 mm (0.47 in) dia. holes in the HUB STAND to prevent bolts from tilting.
DS-21
Front Drive Shaft

DRIVE SHAFT SYSTEM
6. Front Drive Shaft

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Lift up the vehicle, and remove the front wheels. 3) Drain the transmission gear oil. (MT model) 4) Drain the differential gear oil. (AT model) 5) Lift the crimped section of axle nut.
10) Using a bar, remove the front drive shaft from transmission. CAUTION: Be careful not to allow the bar to damage holder area.
B: INSTALLATION
1) Using the ST, replace the differential side retainer oil seal with a new seal. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: After pulling out the drive shaft, be sure to replace with a new oil seal.
ST
DS-00038
6) Remove the axle nut using a socket wrench while depressing the brake pedal. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 7) Remove the stabilizer link from front arm. 8) Disconnect the front arm ball joint from the housing.
MT-00103
2) Insert the EBJ into hub splines. 3) Draw the drive shaft into specified position. CAUTION: Do not hammer drive shaft when installing it. 4) Tighten the axle nut temporarily. 5) Using the ST, install the front drive shaft to transmission. ST 28399SA010 OIL SEAL PROTECTOR
FS-00106
9) Remove the front drive shaft assembly. If it is hard to remove, use ST1 and ST2. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE
ST AT-00110
6) Connect the front arm ball joint to the housing. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb) 7) Install the stabilizer link.
ST2 DS-00145
ST1
Tightening torque: 45 Nm (4.6 kgf-m, 33.2 ft-lb) CAUTION: Be sure to use a new self-locking nut.
DS-22
Front Drive Shaft

DRIVE SHAFT SYSTEM
8) While depressing the brake pedal, tighten a new axle nut to the specified torque and lock it securely. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft-lb) CAUTION: Install the wheel after installation of axle nut. Failure to follow this rule may damage the wheel bearing. Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage the wheel bearing. 9) After tightening axle nut, lock it securely. 10) Fill the transmission gear oil. (MT model) 11) Fill the differential gear oil. (AT model)
4) Remove the PTJ outer race from shaft assembly. 5) Wipe off grease. CAUTION: The grease is a special type of grease. Do not mix with other grease. 6) Place alignment marks on the roller kit and trunnion.
C: DISASSEMBLY
1) Place alignment marks on the shaft and outer race.
DS-00106
2) Remove the PTJ boot band and boot. CAUTION: Be careful not to damage the boot. 7) Remove the roller kit from trunnion.
DS-00109
CAUTION: Be careful with the roller kit position. 8) Place alignment marks on the trunnion and shaft.
DS-00107
3) Remove the snap ring from PTJ outer race.

DS-00110
DS-00108
DS-23
Front Drive Shaft

DRIVE SHAFT SYSTEM
9) Remove the snap ring and trunnion.
6) Align alignment marks on roller kit and trunnion and install the roller kit. CAUTION: Be careful with the roller kit position.
DS-00111
CAUTION: Be sure to wrap shaft splines with vinyl tape to protect the boot from scratches. 10) Remove the PTJ boot. NOTE: The BJ is a non-disassembly part, so the axle disassembly stops here.
D: ASSEMBLY
NOTE: Use specified grease. PTJ side: NKG302 1) Place the PTJ boot at the center of shaft. 2) Align alignment marks and install the trunnion on the shaft.
DS-00109
7) Align the alignment marks of the shaft and outer race, and install the outer race.
DS-00110
DS-00106
3) Install the snap ring to shaft. CAUTION: Confirm that the snap ring is completely fitted in shaft groove. 4) Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of PTJ outer race. 5) Apply a thin coat of specified grease to the roller kit and trunnion.
8) Install the snap ring in the groove on PTJ outer race. CAUTION: Pull the shaft lightly and assure that the snap ring is completely fitted in the groove. 9) Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 oz) to the entire inner surface of boot. 10) Install the PTJ boot taking care not to twist it. CAUTION: The large end of PTJ boot and the boot groove shall be cleaned completely so as to be free from grease and other substances. When installing PTJ boot, position outer race of PTJ at center of its travel.
DS-24
Front Drive Shaft

DRIVE SHAFT SYSTEM
11) Put a new band through the clip and wind twice in the band groove of the boot. 12) Pinch the end of band with pliers. Hold the clip and tighten securely. NOTE: When tightening boot, use care so that the air within the boot is appropriate. 13) Tighten the band using the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten the band until it cannot be moved by hand.
E: INSPECTION
Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace. PTJ (pillow tripod joint) Check for seizure, corrosion, damage, wear and excessive play. EBJ (high-efficiency compact ball fixed joint) Check for seizure, corrosion, damage and excessive play. Shaft Check for excessive bending, twisting, damage and wear. Boot Check for wear, warping, breakage and scratches. Grease Check for discoloration and fluidity.
DS-00132
14) Tap the clip with the punch provided at the end of the ST. ST 925091000 BAND TIGHTENING TOOL CAUTION: Tap to an extent that the boot underneath is not damaged.
DS-00133
15) Cut off the band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip. CAUTION: Make sure that the end of the band is in close contact with clip. 16) Extend and retract the PTJ to provide equal grease coating.
DS-25
Rear Drive Shaft

DRIVE SHAFT SYSTEM
7. Rear Drive Shaft

A: REMOVAL
1) Disconnect the ground cable from battery. 2) Lift up the vehicle, and then remove the rear wheels. 3) Lift the crimped section of axle nut.
B: INSTALLATION
1) Insert the BJ or EBJ into the rear hub splines. CAUTION: Be careful not to damage the magnetic encoder. Do not get closer the tool which charged magnetism to magnetic encoder.
(2) (1)
DS-00038
4) While applying the parking brake, remove the axle nut using a socket wrench. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Remove the rear differential assembly. T-type <Ref. to DI-30, REMOVAL, Rear Differential (Ttype).> VA-type <Ref. to DI-56, REMOVAL, Rear Differential (VAtype).> 6) Remove the axle nut and rear drive shaft. If it is hard to remove, use ST1 and ST2. ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION: Do not hammer drive shaft when removing. Do not damage the oil seal and magnetic encoder.
DS-00251
2) Draw the rear drive shaft into specified position. CAUTION: Do not hammer drive shaft when installing it. 3) Tighten the axle nut temporarily. 4) Install the rear differential assembly. T-type <Ref. to DI-32, INSTALLATION, Rear Differential (T-type).> VA-type <Ref. to DI-58, INSTALLATION, Rear Differential (VA-type).> 5) While applying the parking brake and depressing the brake pedal, tighten a new axle nut to the specified torque and lock it securely. Tightening torque: 240 Nm (24.5 kgf-m, 177 ft-lb) CAUTION: Install the wheel after installation of axle nut. Failure to follow this rule may damage the wheel bearing. Be sure to tighten the axle nut to specified torque. Do not overtighten it as this may damage the wheel bearing.
ST1
ST2
DS-00122
DS-26
Rear Drive Shaft

DRIVE SHAFT SYSTEM
6) Lock the axle nut securely.
7) Wipe off the grease and take out the ball bearings. CAUTION: The grease is a special grease (grease for constant velocity joints). Do not mix with other greases. NOTE: Disassemble exercising care not to lose balls (6 pcs).
DS-00048
7) Install the wheel. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb)
(A)
(B)
C: DISASSEMBLY
1) Straighten the bent claw at the larger end of the DOJ boot. 2) Loosen the band by means of screwdriver or pliers. CAUTION: Be careful not to damage the boot.
(A) Outer race (B) Grease
DS-00126
8) To remove the cage from inner race, turn the cage by a half pitch to the track groove of inner race and shift the cage. 9) Using pliers, remove the snap ring fixing the inner race to the shaft. 10) Take out the DOJ inner race. 11) Take off the DOJ cage from shaft and remove the DOJ boot.
DS-00124
3) Remove the boot band on the small end of DOJ boot in the same manner. 4) Remove the larger end of DOJ boot from DOJ outer race. 5) Pry and remove the round circlip at the neck of DOJ outer race with a screwdriver.
CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches. 12) Remove the BJ boot or EBJ boot in the same procedure as the DOJ boot. NOTE: Further disassembly of axle is impossible because the BJ and EBJ cannot be disassembled.
DS-00125
6) Take out the DOJ outer race from the shaft assembly.
DS-27
Rear Drive Shaft

DRIVE SHAFT SYSTEM
D: ASSEMBLY
NOTE: Use specified grease. BJ, EBJ side: NKG106 DOJ side: NKG205 1) Install the BJ or EBJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 oz.) of specified grease. 2) Place the DOJ boot at the center of shaft. CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches. 3) Insert the DOJ cage onto shaft. NOTE: Insert the cage with the cutout portion facing the shaft end, since the cage has an orientation.
(A)
5) Install the cage to inner race fixed upon shaft. NOTE: Fit the cage with the protruding section aligned with the track on the inner race, and turn by a half pitch.
(A) (B)
DS-00129
(A) Inner race (B) Cage
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the inner side of the DOJ outer race. 7) Apply a thin coat of specified grease to the cage pocket and six ball bearings. 8) Insert the six ball bearings into the cage pocket. 9) Align the outer race track and ball positions, and place the shaft, inner race, cage and ball bearings in the original positions, and then fix outer race in place.
(B) DS-00395 (A) (B)
(A) Cage (B) Cutout portion
4) Install the DOJ inner race on shaft and fix the snap ring in place with pliers. NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
DS-00126
(A) Outer race (B) Grease
DS-00128
DS-28
Rear Drive Shaft

DRIVE SHAFT SYSTEM
10) Install the snap ring in the groove on the DOJ outer race. NOTE: Assure that the balls, cage and inner race are completely fitted in the outer race of DOJ. Use care not to place the matched position of snap ring in the ball groove of outer race. Pull the shaft lightly and assure that the snap ring is completely fitted in the groove.
16) Tap the clip with the punch provided at the end of the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tap to an extent that the boot underneath is not damaged.
DS-00133
DS-00125
17) Cut off the band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip. NOTE: Be careful so that the end of the band is in close contact with clip. 18) Install the BJ boot or EBJ boot in the same procedure as a DOJ boot. 19) Extend and retract the DOJ repeatedly to provide an equal coating of grease.
11) Apply an even coat of the specified grease [20 to 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply grease to the shaft. 12) Install the DOJ boot taking care not to twist it. NOTE: The inside of the large end of DOJ boot and the boot groove shall be cleaned so as to be free from grease and other substances. When installing the DOJ boot, position the outer race of DOJ at center of the stroke. 13) Put a new band through the clip and wind twice in the band groove of the boot. 14) Pinch the end of band with pliers. Hold the clip and tighten securely. NOTE: When tightening boot, use care so that the air within the boot is appropriate. 15) Tighten the band using the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten the band until it cannot be moved by hand.
E: INSPECTION
Check the removed parts for damage, wear, corrosion etc. Repair or replace if defective. DOJ (Double Offset Joint) Check for seizure, corrosion, damage, wear and excessive play. EBJ (High-efficiency Compact Ball Fixed Joint) Check for seizure, corrosion, damage, wear and excessive play. Shaft Check for excessive bending, twisting, damage and wear. BJ (Bell Joint) Check for seizure, corrosion, damage and excessive play. Boot Check for wear, warping, breakage and scratches. Grease Check for discoloration and fluidity.
DS-00132
DS-29

DRIVE SHAFT SYSTEM

A: INSPECTION
NOTE: Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc.
Symptom Noise or vibration from propeller shaft Possible cause Center bearing Corrective action Check the center bearing. <Ref. to DS-12, CENTER BEARING FREE PLAY, INSPECTION, Propeller Shaft.> Check for deflection of the propeller shaft. <Ref. to DS-12, RUNOUT OF PROPELLER SHAFT, INSPECTION, Propeller Shaft.> Check the joints and connectors. <Ref. to DS-12, JOINTS AND CONNECTIONS, INSPECTION, Propeller Shaft.> Check the spline and bearing. <Ref. to DS-12, SPLINES AND BEARING, INSPECTION, Propeller Shaft.> Check the wheel balance. <Ref. to WT-8, ADJUSTMENT, Wheel Balancing.> Check the front wheel alignment. <Ref. to FS-6, INSPECTION, Wheel Alignment.> Check the rear wheel alignment. <Ref. to RS-7, INSPECTION, Wheel Alignment.> Check the front strut. <Ref. to FS-23, INSPECTION, Front Strut.> Check the rear shock absorber. <Ref. to RS-16, INSPECTION, Rear Shock Absorber.> Check the front drive shaft. <Ref. to DS-25, INSPECTION, Front Drive Shaft.> Check the rear drive shaft. <Ref. to DS-29, INSPECTION, Rear Drive Shaft.> Check the front hub unit bearing. <Ref. to DS-18, INSPECTION, Front Hub Unit Bearing.> Check the rear hub unit bearing. <Ref. to DS-21, INSPECTION, Rear Hub Unit Bearing.> Check the wheel balance. <Ref. to WT-8, ADJUSTMENT, Wheel Balancing.> Check the front wheel alignment. <Ref. to FS-6, INSPECTION, Wheel Alignment.> Check the rear wheel alignment. <Ref. to RS-7, INSPECTION, Wheel Alignment.> Check the front strut. <Ref. to FS-23, INSPECTION, Front Strut.> Check the rear shock absorber. <Ref. to RS-16, INSPECTION, Rear Shock Absorber.>
Runout of propeller shaft
Loose or gap at connections
Abnormal wheel vibration
Wheel is out of balance. Front wheel alignment Rear wheel alignment Front strut Rear shock absorber Front drive shaft Rear drive shaft Front hub unit bearing Rear hub unit bearing
Noise from the underbody
Wheel is out of balance. Front wheel alignment Rear wheel alignment Front strut Rear shock absorber
DS-30
General Description
ABS
A: SPECIFICATION
Item ABS wheel speed sensor gap (for reference) ABS wheel speed sensor Identifications of harness (marks, color) G sensor voltage AT (Except for OUTBACK) MT (Except for OUTBACK) AT (OUTBACK) MT (OUTBACK) Front Rear Front Rear RH LH RH LH Specification or identification 0.77 1.43 mm (0.030 0.056 in) 0.64 1.56 mm (0.025 0.061 in) K1 (White) K2 (Yellow) K5 (White) K6 (Yellow) 2.3r0.2 V JG JH JK JM
G sensor
ABSCM&H/U identification
ABS-2
General Description
ABS
B: COMPONENT
1. ABS WHEEL SPEED SENSOR
T1 T1
(1)
T2 T2
(4)
(6) (5) T1 (3)
(2)
T2
ABS00380
(1) (2) (3)
G sensor Front ABS wheel speed sensor LH Front housing
(4) (5) (6)
Rear ABS wheel speed sensor LH Tightening torque:Nm (kgf-m, ft-lb) Hub unit bearing T1: 7.5 (0.76, 5.5) Magnetic encoder T2: 33 (3.3, 24)
ABS-3
General Description
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)

(3) (2) (6) (1) T2 (4) (5) (7)
(9)
(8)
(10) (11)
T1
T2 T2
ABS00938
(1) (2) (3) (4) (5)
ABS control module and hydraulic control unit (ABSCM&H/U) Front outlet RH Rear outlet LH Rear outlet RH Front outlet LH
(6) (7) (8) (9) (10)
Primary inlet Secondary inlet Damper Spacer Damper
(11)
Bracket
Tightening torque:Nm (kgf-m, ft-lb) T1: 7.5 (0.76, 5.5) T2: 33 (3.3, 24)
ABS-4
General Description
ABS
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points.
D: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
2. GENERAL TOOL
TOOL NAME Circuit tester Pressure gauge Oscilloscope TORX bit E5 REMARKS Used for measuring resistance, voltage and current. Used for measuring oil pressure. Used for measuring the sensor. Used for replacing the ABSCM.
ABS-5
ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

ABS
2. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Use compressed air to remove water and dust around the ABSCM&H/U. NOTE: If the terminals become dirty, it may cause improper contact. 3) Lift the lock lever and disconnect the ABSCM&H/U connector. CAUTION: Do not pull on the harness when disconnecting the connector.
B: INSTALLATION
1) Install the ABSCM&H/U bracket. Tightening torque: 33 Nm (3.3 kgf-m, 24 ft-lb) 2) Align the damper groove of the ABSCM&H/U to the bracket side claw, and install the ABSCM&H/U with new nuts (Part No. 023506000). NOTE: Check the identification marks of the ABSCM&H/U. Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
ABS00383
3) Connect the brake pipes to their correct ABSCM&H/U positions.

ABS00382
4) Remove the harness clip. 5) Disconnect the brake pipes from the ABSCM&H/U. 6) Wrap the brake pipe with a vinyl bag so as not to spill the brake fluid on the vehicle body. CAUTION: If brake fluid is spilled on the vehicle body, wash it off immediately with water and wipe clean. 7) Remove the nuts and remove the ABSCM&H/U. CAUTION: Do not drop or bump the ABSCM&H/U. Do not turn the ABSCM&H/U upside down or place it sideways for storage. Be careful not to let foreign matter enter into ABSCM&H/U. Be careful that no water enters the connectors.
Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb) 4) Using a harness clip, secure the ABSCM&H/U harness to the bracket. 5) Connect the connector to the ABSCM&H/U. NOTE: Be sure to remove all foreign matter from inside the connector before connecting. Make sure the ABSCM&H/U connector is securely locked. 6) Bleed air from the brake system.
ABS00383
8) Remove the ABSCM&H/U bracket.
ABS-6

ABS
C: INSPECTION
1) Check the condition of connection and settlement of connector. 2) Check the mark used for ABSCM&H/U identification. Refer to SPECIFICATION for the identification mark. <Ref. to ABS-2, SPECIFICATION, General Description.>
(1)
7) Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression and compression meets the standard values. Depress the brake pedal and check that the kick-back is normal, and tightness is normal.
Initial value When depressurized When pressurized Front wheel Rear wheel 3,500 kPa 3,500 kPa (36 kgf/cm2, 511 psi) (36 kgf/cm2, 511 psi) 500 kPa 500 kPa (5 kgf/cm2, 73 psi) (5 kgf/cm2, 73 psi) or less or less 3,500 kPa 3,500 kPa (36 kgf/cm2, 511 psi) (36 kgf/cm2, 511 psi) or more or more
ABS00384
(1) Identification mark
1. CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE

1) Lift up the vehicle, and remove the wheels. 2) Remove the air bleeder screws from FL and FR caliper bodies. 3) Connect two pressure gauges to FL and FR caliper bodies. CAUTION: Use a pressure gauge used exclusively for brake fluid measurement. Do not use the pressure gauge used for the measurement of transmission oil. Doing so will cause the piston seal to expand and deform. NOTE: Wrap sealing tape around the pressure gauge.
8) Disconnect the pressure gauges from FL and FR caliper bodies. 9) Install the air bleeder screws of FL and FR caliper bodies. 10) Remove the air bleeder screws from RL and RR caliper bodies. 11) Connect two pressure gauges to RL and RR caliper bodies. 12) Bleed air from the brake system. 13) Bleed air from RL and RR caliper bodies, and pressure gauge. 14) Perform ABS sequence control. <Ref. to ABS-10, ABS Sequence Control.> 15) When the hydraulic unit begins to work, first the RR side performs decompression, hold and compression, and then the RL side performs decompression, hold and compression. 16) Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression and compression meets specification. Depress the brake pedal and check that the kick-back is normal, and tightness is normal. 17) Disconnect the pressure gauge from the RL and RR caliper bodies. 18) Install the air bleeder screws of RL and RR caliper bodies. 19) Bleed air from the brake system.
ABS00134
4) Bleed air from the pressure gauges and the FL and FR caliper bodies. 5) Perform ABS sequence control. <Ref. to ABS-10, ABS Sequence Control.> 6) When the hydraulic unit begins to work, first the FL side performs decompression, hold and compression, and then the FR side performs decompression, hold and compression.
ABS-7

ABS
2. CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH THE BRAKE TESTER
1) Install the spare fuse to the FWD connector located in the main fuse box for models without AT VTD.
(1)
7) When the hydraulic unit begins to work, check the following work sequence. (1) The FL wheel performs decompression, hold and compression in sequence, and subsequently the FR wheel repeats the cycle. (2) The RR wheel performs decompression, hold and compression in sequence, and subsequently the RL wheel repeats the cycle. 8) Read values indicated on the brake tester and check if the fluctuation of the values between decompression and compression meets specification.
Initial value Front wheel 1,000 N (102 kgf, 225 lb) 500 N (51 kgf, 112 lb) or less 1,000 N (102 kgf, 225 lb) or more Rear wheel 1,000 N (102 kgf, 225 lb) 500 N (51 kgf, 112 lb) or less 1,000 N (102 kgf, 225 lb) or more
(2)
ABS00392
(1) Main fuse box (2) FWD connector
When depressurized
2) Since the MT model and AT VTD model cannot cut off the AWD circuit, set the wheels other than the measured one on free rollers. 3) Prepare for ABS sequence control. <Ref. to ABS-10, ABS Sequence Control.> 4) Set the front wheels or rear wheels on the brake tester and set the gear to neutral.
When pressurized
9) After the inspection, depress the brake pedal and check that it is not abnormally hard, and tightness is normal.
D: REPLACEMENT
CAUTION: Because the seal of the ABSCM cannot be replaced, do not pull or peel it by lifting it up. Because the screw of the H/U will become slightly worn in every replacement procedure, 5 times is the maximum number of times for replacement. If a problem is found such as not being able to torque the screw to specifications even before 5 replacement operations are performed, replace the H/U body. When installing the ABSCM, always use new screws. When the sealing surface of the ABSCM or H/ U is dirty or damaged and it cannot be removed or repaired, replace with a new part. 1) Remove the ABSCM&H/U bracket. <Ref. to ABS-6, REMOVAL, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> 2) To prevent entry of foreign objects and brake fluid leakage, plug the oil pressure port of the ABSCM&H/U using a screw plug, etc.
(1) ABS00136
(1) ABS00137
(1) Brake tester
5) Operate the brake tester. 6) Perform ABS sequence control. <Ref. to ABS-10, ABS Sequence Control.>
ABS-8

ABS
3) Set the pump motor section of the removed ABSCM&H/U face down on a vise. NOTE: Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise.
9) Using a TORX bit E5, attach/tighten new screws in the order of (1) through (4). CAUTION: Always use new screws. Tightening torque: 1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
(1) (3)
(1) (2)
ABS00430
(4)
(2) ABS00432
(1) Aluminum plate, etc. (2) Vise
4) Using TORX bit E5, remove the four screws of ABSCM. NOTE: These screws cannot be reused.
10) Check that there is no foreign matter in mating surface between the ABSCM and H/U. 11) Using a TORX bit E5, tighten the screws in the order of (1) through (4) again. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb) 12) Check that there is no gap in the mating surface between ABSCM and H/U. 13) Install the ABSCM&H/U to the vehicle.
ABS00431
5) Slowly pull out the ABSCM upward from the H/U. NOTE: To prevent damaging of coil section, remove the ABSCM straight up from H/U without twisting. 6) Make sure there is no dirt or damage on the sealing surface of the H/U. CAUTION: Do not clean the ABSCM and H/U by applying compressed air. Even if damage is found on the H/U seal, do not attempt repair by filing or with a metal scraper. To remove the seal residue, always use a plastic scraper. Do not use chemical such as paint thinner, etc., to clean. 7) Position the coil of the new ABSCM to align with the H/U valve. 8) To prevent deformation of the ABSCM housing cover, hold the corner of ABSCM and install it to the H/U without tilting.
ABS-9
ABS Sequence Control

ABS
3. ABS Sequence Control

A: OPERATION
1) While the ABS sequence control is being performed, the operation of the hydraulic unit can be checked using the brake tester or pressure gauge after the hydraulic unit solenoid valve operation. 2) ABS sequence control can be started by the Subaru Select Monitor.
1. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

NOTE: In the event of any trouble, the ABS sequence control will not operate. 1) Connect the Subaru Select Monitor to data link connector under the drivers side instrument panel lower cover. 2) Turn the ignition switch to ON. 3) Run the PC application for Subaru Select Monitor. 4) Set the Subaru Select Monitor to Brake Control mode. 5) When the Function Check Sequence is selected, the ABS sequence control will start. 6) Execute the following operations when the message Press the brake pedal so that the brake pedal force is between 100 and 150 kgf is displayed. (1) When using a brake tester, press the brake pedal pad with a force of 1,000 N (102 kgf, 225 lb). (2) When using a pressure gauge, press the brake pedal so that the pressure gauge indicates 3,500 kPa (36 kg/cm2, 511 psi). 7) Press the [OK] key after Press OK is displayed. 8) The brake system being operated is displayed on the Subaru Select Monitor.
ABS-10

ABS
2. CONDITIONS FOR ABS SEQUENCE CONTROL

V max < 4 km/h (2.5 MPH) (1) V max < 10 km/h (6 MPH)
(2)
OFF
(15) (17)
ON
(19)
(18) (16)
(19)
(20) (16)
(3)
(16)
(16)
(17)
(17)
(4)
OFF
ON
(5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
OFF OFF OFF
ON
(21) ON (18) ON (21) (18) ON ON ON ON ON ON (22) (23)
OFF OFF OFF OFF OFF OFF OFF
ON
(24) (25) (26) (27) (28)
ABS00943
ABS-11

ABS
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) All wheel speed Ignition key ABS warning light Stop light switch Valve relay FL decompression valve FL compression valve FR decompression valve FR compression valve RR decompression valve (11) (12) (13) (14) (15) (16) (17) (18) (19) RR compression valve RL decompression valve RL compression valve Pump motor 1.5 sec. Light OFF Light ON 1.0 sec. 1.4 sec. (20) (21) (22) (23) (24) (25) (26) (27) (28) 0.6 sec. 0.4 sec. Point A Reset Master cylinder pressure FL wheel cylinder pressure FR wheel cylinder pressure RR wheel cylinder pressure RL wheel cylinder pressure
NOTE: The control operation starts from point A.
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL
When the following conditions develop, the ABS sequence control stops and ABS operation is returned to the normal control mode. 1) When the speed of at least one wheel reaches 10 km/h (6 MPH). 2) When the brake pedal is released during ABS sequence control and the stop light switch is becomes OFF. 3) After completion of ABS sequence control. 4) When a malfunction is detected.
ABS-12
Front ABS Wheel Speed Sensor

ABS
4. Front ABS Wheel Speed Sensor

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Disconnect the ABS wheel speed sensor connector located next to the front strut mounting house in the engine compartment. 3) Remove the sensor harness bracket.
(1)
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Sensor: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb) Bracket: 33 Nm (3.3 kgf-m, 24 ft-lb) CAUTION: Be careful not to damage the sensor. NOTE: Check the identification (mark) on the harness to make sure there is no warpage. (RH: K1 (White), LH: K2 (Yellow)) Check if the harness is not pulled and does not come in contact with the suspension or body during steering wheel effort.
(2)
ABS00386
(1) To the front ABS wheel speed sensor connector (2) Sensor harness bracket
4) Remove the bolts which secure the sensor harness to the front strut. 5) Remove the front ABS wheel speed sensor from housing. CAUTION: Be careful not to damage the sensor. Do not apply excessive force to the sensor harness.
ABS00387
ABS-13

ABS
C: INSPECTION
1. CHECK WITH SUBARU SELECT MONITOR
1) Connect the Subaru Select Monitor to data link connector. 2) Select {Current Data Display & Save}. Check if the speed indicated on the display changes in the same manner as the speedometer reading during acceleration/deceleration when the steering wheel is in the straight-ahead position. 3) If the speed indicated on the display does not change, check the ABS wheel speed sensor. <Ref. to ABS-14, ABS WHEEL SPEED SENSOR, INSPECTION, Front ABS Wheel Speed Sensor.>

1) Check the tip of the ABS wheel speed sensor for foreign particles or damage. If necessary, clean the tip or replace the ABS wheel speed sensor. 2) Connect a 12 V power supply to No. 2 terminal of sensor connector as shown in the figure, then attach resistance to the No. 1 terminal. Rotate the wheel at about 2.75 km/h (2 MPH), and measure the voltage using an oscilloscope. Standard value of output voltage: 0.7 1.4 V
1.4 V 0.7 V
(1) 12 V 1 (2) 2 2 1
100
ABS00388
(1) Oscilloscope (2) ABS wheel speed sensor
NOTE: Check the ABS wheel speed sensor cable for discontinuity. If necessary, replace with a new part.
ABS-14
Rear ABS Wheel Speed Sensor

ABS
5. Rear ABS Wheel Speed Sensor

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Disconnect the connector from the rear ABS wheel speed sensor.
4) Remove the rear ABS wheel speed sensor from the rear arm. CAUTION: Be careful not to damage the sensor. Do not apply excessive force to the sensor harness.
ABS00390 ABS00389
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Be careful not to damage the sensor. Tightening torque: Sensor: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb) Bracket: 33 Nm (3.3 kgf-m, 24 ft-lb) NOTE: Check the identification (mark) on the harness to make sure there is no warpage. (RH: K5 (White), LH: K6 (Yellow))
3) Remove the sensor harness bracket from the rear arm.
ABS00166
C: INSPECTION
<Ref. to ABS-14, ABS WHEEL SPEED SENSOR, INSPECTION, Front ABS Wheel Speed Sensor.>
ABS00167
ABS00168
ABS-15
Front Magnetic Encoder

ABS
6. Front Magnetic Encoder

A: REMOVAL
Refer to Front Hub Bearing for removal, because the front magnetic encoder is integrated with front hub bearing. <Ref. to DS-17, REMOVAL, Front Hub Unit Bearing.>
B: INSTALLATION
Refer to Front Hub Bearing for installation, because the front magnetic encoder is integrated with front hub bearing. <Ref. to DS-18, INSTALLATION, Front Hub Unit Bearing.>
C: INSPECTION
Visually check the magnetic encoder for any damage. If necessary, replace with a new hub unit bearing. NOTE: Because the magnetic encoder is integrated with front hub unit bearing assembly, replace the hub unit bearing with a new part if there is any defect found on the magnetic encoder.
ABS-16
Rear Magnetic Encoder

ABS
7. Rear Magnetic Encoder

A: REMOVAL
Refer to Rear Hub Unit Bearing for removal, because the rear magnetic encoder is integrated with rear hub unit bearing. <Ref. to DS-19, REMOVAL, Rear Hub Unit Bearing.>
B: INSTALLATION
Refer to Rear Hub Unit Bearing for installation, because the rear magnetic encoder is integrated with rear hub unit bearing. <Ref. to DS-20, INSTALLATION, Rear Hub Unit Bearing.>
C: INSPECTION
Visually check the magnetic encoder parts for any damage. If necessary, replace with a new hub unit bearing. NOTE: Because the magnetic encoder is integrated with rear hub unit bearing assembly, replace the hub unit bearing with a new part if there is any defect found on the magnetic encoder.
ABS-17
G Sensor
ABS
8. G Sensor
A: REMOVAL
1) Disconnect the ground cable from battery. 2) Remove the console box. <Ref. to EI-54, REMOVAL, Console Box.> 3) Disconnect the connector from G sensor. 4) Remove the G sensor from the body. CAUTION: Do not drop or bump the G sensor. The G sensor integrated with the bracket. Do not disassemble.
ABS00463
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Do not drop or bump the G sensor. Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
1 Step CHECK G SENSOR. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Set the Subaru Select Monitor to the {Brake Control System} mode. 4) Set the display in the {Current Data Display & Save} mode. 5) Read the G sensor output value. CHECK G SENSOR. 1) Remove the console box. 2) Remove the G sensor from vehicle. (Do not disconnect the connector.) 3) Read the Subaru Select Monitor display. CHECK G SENSOR. Read the Subaru Select Monitor display. Check Yes Go to step 2. Is the value 1.2 1.2 m/s2 when the vehicle is in horizontal position? No Repair the harness connector between the G sensor and ABSCM&H/U. Or replace G sensor.
Is the value 8.1 11.2 m/s2 when G sensor is inclined forward to 90?
Go to step 3.
Is the value 8.1 11.2 m/s2 G sensor is norwhen G sensor is inclined back- mal. ward 90?
Repair the harness connector between the G sensor and ABSCM&H/U. Or replace G sensor. Repair the harness connector between the G sensor and ABSCM&H/U. Or replace G sensor.
ABS-18

ABS (DIAGNOSTICS)

A: PROCEDURE
CAUTION: Remove foreign matter (dust, water, oil etc.) from the ABSCM&H/U connector during removal and installation. NOTE: To check harness for open or short circuits, shake the suspected trouble spot or connector. Refer to Check List for Interview. <Ref. to ABS(diag)-3, Check List for Interview.>
1 Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to ABS(diag)-3, Check List for Interview.> 2) Before performing diagnostics, check the components which might affect ABS problems. <Ref. to ABS(diag)-7, INSPECTION, General Description.> CHECK INDICATION OF DTC ON SCREEN. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON and run the Subaru Select Monitor. NOTE: If the communication function of the Subaru Select Monitor cannot be executed properly, check the communication circuit. <Ref. to ABS(diag)-15, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.> 4) Read the DTC. <Ref. to ABS(diag)-18, OPERATION, Read Diagnostic Trouble Code (DTC).> 5) Record all DTCs and freeze frame data. PERFORM GENERAL DIAGNOSIS. 1) Perform the inspection by referring to General Diagnostic Table. <Ref. to ABS(diag)-62, General Diagnostic Table.> 2) Perform the Clear Memory Mode. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. <Ref. to ABS(diag)-18, Read Diagnostic Trouble Code (DTC).> Check the DTC is not displayed. PERFORM DIAGNOSIS. 1) Refer to List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, LIST, List of Diagnostic Trouble Code (DTC).> 2) Correct the cause of trouble. 3) Perform the Clear Memory Mode. <Ref. to ABS(diag)-20, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 5) Read the DTC. <Ref. to ABS(diag)-18, Read Diagnostic Trouble Code (DTC).> Check Yes Are components which might Go to step 2. affect the ABS problem operating correctly? No Repair or replace each component.
Is DTC displayed?
Go to step 4.
Go to step 3.
Does the ABS warning light go Finish the diagno- Check the combisis. nation meter ciroff after turning the ignition cuit. <Ref. to switch to ON? ABS(diag)-25, ABS WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.> Is DTC displayed? Repeat step 1 to 4 Finish the diagnountil DTC does not sis. appear.
ABS(diag)-2

ABS (DIAGNOSTICS)

A: CHECK
Check the following items regarding condition of the vehicle.
1. STATE OF ABS WARNING LIGHT

ABS warning light illuminates. Always Sometimes Only once Does not come on When and for how long does it illuminate? LOCK ACC ON (before starting engine) START ON (after starting engine, engine is running) ON (after starting engine, engine is at a standstill) Immediately after turning the ignition ON. Immediately after turning the ignition to START. While accelerating While driving at a constant speed While decelerating When turning to the right When turning to the left When other electrical parts are operating Parts name: Operating condition: Steering angle: Steering time: Steering angle: Steering time:
Ignition key position
Timing
km/h
km/h MPH MPH km/h MPH deg Sec. deg Sec.
ABS(diag)-3

ABS (DIAGNOSTICS)
2. STATE OF BRAKE WARNING LIGHT

Brake warning light illuminates. Always Sometimes Only once Does not come on When pulling the parking brake lever. When releasing the parking brake lever. When and for how long does it illuminate? LOCK ACC ON (before starting engine) START ON (after starting engine, engine is running) ON (after starting engine, engine is at a standstill) Immediately after turning the ignition ON. Immediately after turning the ignition to START. While accelerating While driving at a constant speed While decelerating When turning to the right When turning to the left When other electrical parts are operating Parts name: Operating condition: Steering angle: Steering time: Steering angle: Steering time:
Timing
km/h
ABS(diag)-4

ABS (DIAGNOSTICS)
3. SYMPTOMS
ABS operating condition Does not operate. Operates only when applying the brakes suddenly. Procedures for stepping on the brake pedal: a) Operating time: b) Operating noise: Occurs. / Does not occur. What kind of noise? Vehicle speed: km/h MPH Sec. Knocking Gong gong Thump Buzz Gong gong buzz Others:
c) Reaction force of brake pedal Sticks Weak pedal resistance Strong pedal resistance Others: a) Directional stability cannot be obtained or the steering does not respond when applying brakes: Yes / No When: When turning to the right When turning to the left When spinning out Others: b) Directional stability cannot be obtained or the steering does not respond when accelerating: Yes / No When: When turning to the right When turning to the left When spinning out Others: c) Poor brake performance: Yes / No What kind: Braking distance is long. Brakes lock or drag. Pedal stroke is long. Pedal sticks. Others: d) Poor acceleration: Yes / No What kind: Fails to accelerate. Engine stalls. Others: e) Occurrence of vibration: Yes / No Where What kind: f) Occurrence of noise: Yes / No Where What kind: g) Other troubles occurred: Yes / No What kind:
Condition of vehicle
ABS(diag)-5

ABS (DIAGNOSTICS)
4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment a) Weather Fine Cloudy Rainy Snowy Others: C ( Inner city Suburbs Highway Local street Uphill Downhill Paved road Gravel road Muddy road Sandy place Others: Dry Wet Covered with fresh snow Covered with hardened snow Frozen slope Others: Deceleration: Intermittent / Temporary Acceleration: Intermittent / Temporary km/h Advancing While accelerating While decelerating At low speed When turning Others: Front RH tire: Front LH tire: Rear RH tire: Rear LH tire: Front RH tire: Front LH tire: Rear RH tire: Rear LH tire: F)
b) Ambient temperature c) Road
d) Road surface
Condition
a) Brakes b) Accelerator c) Vehicle speed
G G MPH
d) Tire inflation pressure
kPa kPa kPa kPa
e) Degree of wear
f) Genuine parts are used.: Yes / No g) Tire chain is attached: Yes / No h) T-type tire is used.: Yes / No i) Condition of suspension alignment: j) Loaded state: k) Repair parts are used.: Yes / No Contents: l) Others:
ABS(diag)-6
General Description
ABS (DIAGNOSTICS)
A: CAUTION
Airbag system wiring harness is routed near the ABS wheel speed sensor and ABSCM&H/U. CAUTION: All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage the airbag system wiring harness when servicing the ABS wheel speed sensor and ABSCM&H/U.
3. BRAKE FLUID
1) Check the brake fluid level. 2) Check the brake fluid for leaks.
4. HYDRAULIC UNIT
Check the hydraulic unit. When using the brake tester <Ref. to ABS-8, CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH THE BRAKE TESTER, INSPECTION, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> When not using the brake tester <Ref. to ABS-7, CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE, INSPECTION, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
B: INSPECTION
Before performing diagnosis, check the following item which might affect ABS problems.
5. BRAKE DRAG
Check for brake drag.
1. BATTERY
Measure the battery voltage and check electrolyte. Standard voltage: 12 V or more Specific gravity: 1.260 or more
6. BRAKE PAD AND ROTOR

Check the brake pad and rotor. Front <Ref. to BR-13, INSPECTION, Front Brake Pad.> <Ref. to BR-14, INSPECTION, Front Disc Rotor.> Rear <Ref. to BR-19, INSPECTION, Rear Brake Pad.> <Ref. to BR-21, INSPECTION, Rear Disc Rotor.>
2. GROUND
Check the tightening torque of ground (GB-7) bolt of ABS. Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
7. TIRE
Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATION, General Description.>
C: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
2. GENERAL TOOL
ABS(diag)-7

ABS (DIAGNOSTICS)

A: LOCATION
(5) (4)
(2) (1)
(6) (7) (9) (3) (10) (12) (8) (7) (6) (11) (8)
ABS00591
(1) (2) (3)
ABS control module and hydraulic control unit (ABSCM&H/U) Two-way connector Data link connector (For Subaru Select Monitor)
(4) (5) (6) (7) (8)
ABS warning light Brake and EBD warning light Caliper body Magnetic encoder seal ABS wheel speed sensor
(9) (10) (11) (12)
G sensor Transmission control module (TCM) (AT model) Stop light switch Master cylinder
ABS(diag)-8

ABS (DIAGNOSTICS)
(1)
(5) (4) ABS00405 (8) FRONT (3) (7) ABS01068
ABS00600 (8) REAR (7)
(7)
ABS00408
(9) (7)
ABS00407
ABS00599
ABS(diag)-9

ABS (DIAGNOSTICS)

(1)
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS00409
(1)
ABS control module and hydraulic control unit (ABSCM&H/U) connector
NOTE: Terminal numbers in ABSCM&H/U connector are shown in the figure. ABS warning light illuminates when the connector is removed from ABSCM&H/U.
ABS(diag)-10

ABS (DIAGNOSTICS)
Terminal No. (+) () 16 15 1 5 15 6 2 15 17 3 15 4 26 11 14 15 13 15 24 10 10 21 10 20 15 22 15 8 15 7 15 18 15 15 23 15 Input/Output signal Measured value and measuring conditions 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 2.5 1.5 V pulse signal 3.5 2.5 V pulse signal 10 15 V 10 15 V 4.75 5.25 V 2.1 2.5 V when the vehicle is on level surface 1.5 V or less when the stop light is OFF; otherwise, 10 15 V when the stop light is ON. After turning the ignition switch to ON, 10 15 V during 1.5 seconds and 1.5 V or less after 1.5 seconds passed. After turning the ignition switch to ON, 10 15 V during 1.5 seconds and 1.5 V or less after 1.5 seconds passed. 1.5 V or less when no data is received. 0 mo 12 V pulse (in communication) 10 15 V when the ignition switch is ON. 0 mo 5 V pulse
Description Power supply Signal Power supply Front RH wheel Signal ABS wheel speed sensor (Wheel speed sensor) Power supply Rear LH wheel Signal Power supply Rear RH wheel Signal CAN communication line (+) CAN communication line () Valve relay power supply *1 Motor relay power supply *1 Power supply G sensor Ground Output Front LH wheel Stop light switch *1 ABS warning light Brake warning light (EBD warning light) Subaru Select Monitor Power supply *1 Grounding line Vehicle speed output signal
*1: Measure the I/O signal voltage after disconnecting the connector from the ABSCM&H/U terminal.
ABS(diag)-11

ABS (DIAGNOSTICS)
B: WIRING DIAGRAM
(3)
(16) (17) (1) (18) (5)
(19) (2) (20) (6) (22) (23) (4) (24)
(21)
M
(25)
(7) (8) (9)
(26)
(10) (11) (12)
(27) (28) (29) (30)
(13) (14) (15)
ABS01083
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Battery Ignition switch ABS control module and hydraulic control unit (ABSCM&H/U) ABS control module Valve relay Motor relay Motor Front inlet solenoid valve LH Front outlet solenoid valve LH Front inlet solenoid valve RH
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Front outlet solenoid valve RH Rear inlet solenoid valve LH Rear outlet solenoid valve LH Rear inlet solenoid valve RH Rear outlet solenoid valve RH Body integrated unit Engine control module (ECM) Transmission control module (TCM) Data link connector ABS warning light
(21) (22) (23) (24) (25) (26) (27) (28) (29) (30)
Brake warning light Parking brake switch Brake fluid level switch Stop light switch Stop light G sensor Front ABS wheel speed sensor LH Front ABS wheel speed sensor RH Rear ABS wheel speed sensor LH Rear ABS wheel speed sensor RH
ABS(diag)-12

ABS (DIAGNOSTICS)

A: OPERATION
1. HOW TO USE SUBARU SELECT MONITOR
1) Prepare the Subaru Select Monitor kit. <Ref. to ABS(diag)-7, SPECIAL TOOL, PREPARATION TOOL, General Description.>
(1)
ABS00465
EN-05692
2) Prepare PC with Subaru Select Monitor installed. 3) Connect the USB cable between SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 4) Connect the diagnosis cable to SDI.
CAUTION: Do not connect scan tools other than the Subaru Select Monitor. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. 8) If communication is not possible between the ABS and the Subaru Select Monitor, check the communication circuit. <Ref. to ABS(diag)-15, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.>

1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Brake Control System}. 3) Click the [OK] button after the {ABS} is displayed. 4) On the Brake Control Diagnosis display, select the {Current Data Display & Save}. 5) On the Data Display Menu display, select the data display method. 6) Using the scroll key, scroll the display screen up or down until necessary data is shown. A list of the support data is shown in the following table.
Display FR Wheel Speed FL Wheel Speed RR Wheel Speed RL Wheel Speed BLS Signal G-Sensor Valve Relay Signal ABS Warning Light EBD Warning Light M. Relay monitor Voltage ABS_CM Power Voltage ABS Control Flag ABS OK B Signal Contents to be displayed Wheel speed detected by front ABS wheel speed sensor RH is displayed. Wheel speed detected by front ABS wheel speed sensor LH is displayed. Wheel speed detected by rear ABS wheel speed sensor RH is displayed. Wheel speed detected by rear ABS wheel speed sensor LH is displayed. Brake ON/OFF is displayed. Vehicle acceleration detected by analog G sensor is displayed. Valve relay operation signal is displayed. ON operation of the ABS warning light is displayed. ON operation of the EBD warning light is displayed. Motor relay monitor voltage is displayed. Voltage supplied to ABSCM&H/U is displayed. ABS control condition is displayed. ABS system normal/abnormal is displayed. Unit of measure km/h or MPH km/h or MPH km/h or MPH km/h or MPH ON or OFF m/s (m/s2) ON or OFF ON or OFF ON or OFF V V ON or OFF OK or NG
ABS(diag)-13

ABS (DIAGNOSTICS)
3. ABS SEQUENCE CONTROL

Display ABS Sequence Control Mode Contents to be displayed Operate the valve and pump motor continuously to perform the ABS sequence control. Index No. <Ref. to ABS10, ABS Sequence Control.>
4. FREEZE FRAME DATA

NOTE: Data stored at the time of trouble occurrence is shown on display. Each time a trouble occurs, the latest information is stored in the freeze frame data in memory. Up to 3 freeze frame data will be stored. If freeze frame data is not stored in memory properly (due to a drop in ABS control module power supply etc.), a DTC suffixed with a question mark ? is displayed on Subaru Select Monitor display screen. This shows it may be an unreliable reading.
Contents to be displayed Wheel speed detected by front ABS FR Wheel wheel speed sensor RH is displayed in Speed km/h or MPH. Wheel speed detected by front ABS FL Wheel Speed wheel speed sensor LH is displayed in km/h or MPH. Wheel speed detected by rear ABS RR Wheel wheel speed sensor RH is displayed in Speed km/h or MPH. Wheel speed detected by rear ABS RL Wheel wheel speed sensor LH is displayed in Speed km/h or MPH. ABS_CM Power Voltage (V) supplied to ABSCM&H/U is Voltage displayed. Vehicle acceleration detected by analog G-Sensor G sensor is displayed. M. Relay monitor Motor relay condition is displayed. Voltage BLS Signal Brake ON/OFF is displayed. Vehicle speed calculated by ABS control Vehicle Speed module is displayed. ABS Control ABS control condition is displayed. Flag Power Supply Whether abnormal voltage occurred or Failure not is displayed during malfunction. Display
ABS(diag)-14

ABS (DIAGNOSTICS)
B: INSPECTION
DETECTING CONDITION: Defective harness connector TROUBLE SYMPTOM: Communication is impossible between ABS and Subaru Select Monitor. WIRING DIAGRAM:
BATTERY
MAIN SBF
SBF-6
IGNITION SWITCH DATA LINK CONNECTOR 16 7 No.33 B40
No.13
E
18 15 B301 7 B301 ABSCM & H/U 12 13 14 15
B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS00905
ABS(diag)-15

ABS (DIAGNOSTICS)
Step CHECK IGNITION SWITCH. Check Is the ignition switch ON? Yes Go to step 2. No Turn the ignition switch to ON, and select ABS mode using Subaru Select Monitor. Charge or replace the battery. Go to step 4.
10
Is there poor contact at the bat- Repair or tighten tery terminal? the battery terminal. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Go to step 8. MUNICATION. on the Subaru Select Monitor? 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to other systems can be executed normally. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Replace the MUNICATION. on the Subaru Select Monitor? ABSCM&H/U. 1) Turn the ignition switch to OFF. <Ref. to ABS-6, 2) Disconnect the ABSCM&H/U connectors. ABS Control Mod3) Turn the ignition switch to ON. ule and Hydraulic 4) Check whether communication to other sysControl Unit tems can be executed normally. (ABSCM&H/U).> CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 7. EACH CONTROL MODULE AND DATA LINK more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U, ECM and TCM. 3) Measure the resistance between data link connector and chassis ground. Connector & terminal (B40) No. 7 Chassis ground: Is the voltage less than 1 V? Go to step 8. CHECK ABSCM&H/U OUTPUT SIGNAL. 1) Turn the ignition switch to ON. 2) Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 7 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 :? Go to step 9. ABSCM&H/U AND DATA LINK CONNECTOR. Measure the resistance between ABSCM&H/U connector and data link connector. Connector & terminal (B301) No. 7 (B40) No. 7: CHECK INSTALLATION OF ABSCM&H/U Is the ABSCM&H/U connector Go to step 10. CONNECTOR. inserted into ABSCM&H/U until the clamp locks onto it? Turn the ignition switch to OFF. CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 15 V? Go to step 11. 1) Turn the ignition switch to ON. (engine OFF) 2) Measure the ignition power supply voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 18 (+) Chassis ground ():
CHECK BATTERY. 1) Turn the ignition switch to OFF. 2) Measure the battery voltage. CHECK BATTERY TERMINAL.
Go to step 3.
Go to step 5.
Go to step 6.
Repair the harness and connector between each control module and data link connector. Repair harness and connector between ABSCM&H/U and data link connector. Insert ABSCM&H/ U connector into ABSCM&H/U. Repair open circuit of harness between ABSCM&H/U and battery.
ABS(diag)-16

ABS (DIAGNOSTICS)
Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 :? Go to step 12. ABSCM&H/U AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Measure the resistance of the harness between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 15 Chassis ground: CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in control Repair the connecmodule power supply, ground tor. circuit and data link connector? No Repair the open circuit and poor contact of the harness between ABSCM&H/U and connector.
11
12
Replace the ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS(diag)-17

ABS (DIAGNOSTICS)

A: OPERATION
1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Brake Control System}. 3) Click the [OK] button after the {ABS} is displayed. 4) On the Brake Control Diagnosis display, select the {Diagnostic Code(s) Display}. 5) Record the DTC and data. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor. For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)29, List of Diagnostic Trouble Code (DTC).> Up to 3 DTCs are displayed in the order of detection. If a particular DTC is not stored in memory properly at the occurrence of problem (due to a drop in ABSCM&H/U power supply etc.), the DTC suffixed with a question mark ? is displayed on Subaru Select Monitor display screen. This shows it may be an unreliable reading. If No diagnostic Code Present is displayed, check combination meter or harness. <Ref. to ABS(diag)-25, ABS WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.> When the ABS warning light is OFF and No diagnostic Code Present is displayed, the system is operating properly.
Display (Current) (Old) Contents to be displayed The current DTC is displayed on Subaru Select Monitor display screen. The latest DTC in previous troubles is displayed on Subaru Select Monitor display screen. The second latest DTC from the history of previous problems is displayed on the Subaru Select Monitor display screen. The third latest DTC from the history of previous problems is displayed on Subaru Select Monitor display screen.
(Older)
(Before 3)
ABS(diag)-18
Inspection Mode
ABS (DIAGNOSTICS)
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition as much as possible. Drive the vehicle at a speed of 40 km/h (25 MPH) or more for at least one minute.
ABS(diag)-19
Clear Memory Mode

ABS (DIAGNOSTICS)

A: OPERATION
1) On the Main Menu display, select {Each System Check}. 2) On the System Selection Menu display, select the {Brake Control System}. 3) Click the [OK] button after the {ABS} is displayed. 4) On the Brake Control Diagnosis display, select the {Clearing Memory}. 5) When the Clear Memory? is shown on the screen, click the [Yes] button. 6) When Done and Turn Ignition Switch OFF are shown on the display screen, turn the ignition switch to OFF. NOTE: For detailed operation procedures, refer to the PC application help for Subaru Select Monitor.
ABS(diag)-20
ABS Warning Light / Brake Warning Light Illumination Pattern

ABS (DIAGNOSTICS)
10.ABS Warning Light / Brake Warning Light Illumination Pattern

A: INSPECTION
(4)
(3) (2) (1) (7)
(3)
(6) (5) (8)
(6)
(7)
(6) (9)
(6)
(10) (11)
ABS00442
(1) (2) (3) (4)
Ignition switch OFF ON Engine start
(5) (6) (7) (8)
ABS warning light Light OFF Light ON 1.5 sec.
(9) (10) (11)
Brake warning light (EBD warning light) Parking brake Released
ABS(diag)-21

ABS (DIAGNOSTICS)
1) When the ABS warning light and brake warning light do not illuminate in accordance with this illumination pattern, it can be thought that there is an electrical problem. 2) When the ABS warning light remains constantly OFF, check the combination meter circuit. <Ref. to ABS(diag)-23, ABS WARNING LIGHT DOES NOT COME ON, ABS Warning Light / Brake Warning Light Illumination Pattern.> 3) When ABS warning light does not go off, check the combination meter circuit. <Ref. to ABS(diag)25, ABS WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.> 4) When the brake warning light does not go off, check the brake warning circuit and the combination meter circuit. <Ref. to ABS(diag)-27, BRAKE WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.> NOTE: Even though the ABS warning light does not go off after approximately 1.5 seconds from ABS warning light illumination, the ABS function operates normally when the warning light goes off while driving at approximately 12 km/h (7 MPH). However, the ABS system does not work while the ABS warning light is illuminated.
ABS(diag)-22

ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT COME ON

DETECTING CONDITION: Defective combination meter Defective harness TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), ABS warning light does not illuminate. WIRING DIAGRAM:
BATTERY MAIN SBF
SBF-6
E
No.33
BRAKE WARNING LIGHT
A3 ABS WARNING LIGHT
COMBINATION METER A: B: i10 i11
*1
: NORMAL METER METER WITH MID
: A5 : B5
REVERSE CIRCUIT
REVERSE CIRCUIT
A7
*1
i3 9 B38
20
18
22
15
B301
ABSCM & H/U
A:
i10
B:
i11
B301
B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS01069
ABS(diag)-23

ABS (DIAGNOSTICS)
Step CHECK ILLUMINATION OF OTHER LIGHTS. Turn the ignition switch to ON. (engine OFF) READ DTC. Read the DTC. <Ref. to ABS(diag)-18, Read Diagnostic Trouble Code (DTC).> CHECK GROUND SHORT OF HARNESS. 1) Turn the ignition to OFF. 2) Disconnect the connector (B301) from the ABSCM&H/U. 3) Disconnect the connector (i10) (Model with the normal meter) or (i11) (Model with the meter with MID) from the combination meter. 4) Measure the resistance between ABSCM connector and chassis ground. Connector & terminal (B301) No. 22 Chassis ground: CHECK ABSCM. 1) Connect the connector (B301) to the ABSCM&H/U. 2) Turn the ignition to ON. 3) Measure the resistance between the combination meter connector and chassis ground soon after the ignition switch is turned to ON (within 1.5 seconds). Connector & terminal Model with the normal meter (i10) No. 5 Chassis ground: Model with the meter with MID (i11) No. 5 Chassis ground: Check Do other warning lights illuminate? Is DTC displayed? Yes Go to step 2. No Check the combination meter. Go to step 3.
1 2
Perform the diagnosis according to DTC. Go to step 4. Repair harness and connector between ABSCM&H/U and combination meter.
Replace the ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS(diag)-24

ABS (DIAGNOSTICS)
C: ABS WARNING LIGHT DOES NOT GO OFF

DETECTING CONDITION: Defective combination meter Open circuit in harness TROUBLE SYMPTOM: When starting the engine, the ABS warning light is kept on. WIRING DIAGRAM:
BATTERY MAIN SBF
SBF-6
E
No.33
BRAKE WARNING LIGHT
*1
: NORMAL METER METER WITH MID
: A5 : B5
REVERSE CIRCUIT
REVERSE CIRCUIT
A7
*1
i3 9 B38
20
18
22
15
B301
ABSCM & H/U
A:
i10
B:
i11
B301
B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS01069
ABS(diag)-25

ABS (DIAGNOSTICS)
Step READ DTC. Read the DTC. <Ref. to ABS(diag)-18, Read Diagnostic Trouble Code (DTC).> CHECK WIRING HARNESS. 1) Turn the ignition to OFF. 2) Disconnect the connector (B301) from the ABSCM&H/U. 3) Disconnect the connector (i10) (Model with the normal meter) or (i11) (Model with the meter with MID) from the combination meter. 4) Measure the resistance between ABSCM connector and combination meter connector. Connector & terminal Model with the normal meter (B301) No. 22 (i10) No. 5: Model with the meter with MID (B301) No. 22 (i11) No. 5: CHECK POOR CONTACT IN CONNECTOR. Check for poor contact in all connectors. CHECK ABSCM. 1) Connect the connector (B301) to the ABSCM&H/U. 2) Turn the ignition switch to ON. 3) Measure the resistance between combination meter connector and chassis ground. Connector & terminal Model with the normal meter (i10) No. 5 Chassis ground: Model with the meter with MID (i11) No. 5 Chassis ground: Yes No Perform the diag- Go to step 2. nosis according to DTC. Is the resistance less than 0.5 :? Go to step 3. Repair harness and connector between ABSCM&H/U and combination meter. Check Is DTC displayed?
3 4
Repair the connec- Go to step 4. tor. Is the resistance less than 0.5 :? Check the combi- Replace the nation meter. ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
Is there poor contact?
ABS(diag)-26

ABS (DIAGNOSTICS)
D: BRAKE WARNING LIGHT DOES NOT GO OFF

DETECTING CONDITION: Brake warning light circuit is shorted. Defective sensor/connector TROUBLE SYMPTOM: After starting the engine, the brake warning light remains lit though the parking lever is released. WIRING DIAGRAM:
BATTERY MAIN SBF
SBF-6
E
A3
PARKING BRAKE FLUID LEVEL WARNING LIGHT

REVERSE CIRCUIT
*1
: NORMAL METER : A8 METER WITH MID : A4 : NORMAL METER : B10 METER WITH MID : A8
*2
A7
*2
i3 B38 20 15 16
*1
i1 B36
B16 1 2 BRAKE FLUID LEVEL SWITCH 8 B301 ABSCM & H/U B404
E
PARKING SWITCH
B16
i1
B301
A:
i10
1 2
3 4 1 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B38 B:
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
i11
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ABS01070
ABS(diag)-27

ABS (DIAGNOSTICS)
Step CHECK INSTALLATION OF ABSCM&H/U CONNECTOR. 1) Turn the ignition switch to OFF. 2) Check that the ABSCM&H/U connector is inserted to ABSCM&H/U until the clamp locks onto it. READ DTC. Read the DTC. <Ref. to ABS(diag)-18, Read Diagnostic Trouble Code (DTC).> CHECK BRAKE FLUID AMOUNT. Check the amount of brake fluid in the reservoir tank of the master cylinder. CHECK BRAKE FLUID LEVEL SWITCH. 1) Disconnect the level switch connector (B16) from master cylinder. 2) Measure the resistance of master cylinder terminals. Terminals No. 1 No. 2: CHECK PARKING BRAKE SWITCH. 1) Disconnect the connector (B404) from parking brake switch. 2) Release the parking brake. 3) Measure the resistance between parking brake switch terminal and chassis ground. CHECK GROUND SHORT OF HARNESS. 1) Disconnect the connectors (i10 and i11) from the combination meter. 2) Measure the resistance between combination meter connector and chassis ground. Connector & terminal Model with the normal meter (i10) No. 8 Chassis ground: (i11) No. 10 Chassis ground: Model with the meter with MID (i10) No. 8 Chassis ground: (i10) No. 4 Chassis ground: CHECK HARNESS. 1) Disconnect the connector (B301) from the ABSCM&H/U. 2) Disconnect the connector (i10) from the combination meter. 3) Measure the resistance between the ABSCM&H/U connector and combination meter connector. Connector & terminal (B301) No. 8 (i10) No. 7: CHECK POOR CONTACT IN CONNECTOR. Check for poor contact in all connectors. CHECK ABSCM. 1) Connect the connector to the ABSCM&H/U. 2) Turn the ignition switch to ON. 3) Measure the resistance between combination meter connector and chassis ground. Connector & terminal (i10) No. 7 Chassis ground: Check Is the connector firmly inserted? Yes Go to step 2. No Insert the ABSCM&H/U connector until the clamp locks completely.
Is DTC displayed?
Perform the diag- Go to step 3. nosis according to DTC. Is the amount of brake fluid Go to step 4. Replenish brake between the lines of MAX and fluid to the speciMIN? fied value. Is the resistance 1 M: or Go to step 5. Replace the masmore? ter cylinder.
Go to step 6.
Replace the parking brake switch.
Go to step 7.
Repair the harness connector between combination meter and parking brake switch.
Is the resistance less than 0.5 :? Go to step 8.
Repair the harness between the ABSCM&H/U and the combination meter.
8 9
Repair the connec- Go to step 9. tor. Is the resistance less than 0.5 :? Check the combi- Replace the nation meter. ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Is there poor contact?
ABS(diag)-28

ABS (DIAGNOSTICS)

A: LIST
DTC Content of diagnosis Rear ABS wheel speed sensor RH Display Rear Right ABS Sensor Circuit Open or Shorted Battery Reference target <Ref. to ABS(diag)-31, DTC C0101 ABS WHEEL SPEED SENSOR MALFUNCTION RR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-31, DTC C0102 ABS WHEEL SPEED SENSOR MALFUNCTION RL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-31, DTC C0103 ABS WHEEL SPEED SENSOR MALFUNCTION FR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-32, DTC C0104 ABS WHEEL SPEED SENSOR MALFUNCTION FL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-34, DTC C0105 REAR ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-34, DTC C0106 REAR ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-34, DTC C0107 FRONT ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-35, DTC C0108 FRONT ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-47, DTC C0109 POWER VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0101
C0102 ABS wheel speed sensor malfunction (Broken wire, short) C0103
Rear ABS wheel speed sensor LH
Rear Left ABS Sensor Circuit Open or Shorted Battery
Front ABS wheel speed sensor RH
Front Right ABS Sensor Circuit Open or Shorted Battery
C0104
Front ABS wheel speed sensor LH
Front Left ABS Sensor Circuit Open or Shorted Battery
C0105
Abnormal signal of rear ABS Rear Right ABS Senwheel speed sensor Signal sor RH Abnormal signal of rear ABS Rear Left ABS Sensor wheel speed sen- Signal ABS wheel speed sensor LH sor malfunction (ABS wheel speed sensor Abnormal signal abnormal signal) of front ABS Front Right ABS Senwheel speed sensor Signal sor RH Abnormal signal of front ABS Front Left ABS Sensor wheel speed sen- Signal sor LH Power voltage malfunction Power Supply Voltage Failure
C0106
C0107
C0108
C0109
C0110
ABS control module malfunction
C0111
Motor/motor relay on failure
C0114
Defective valve relay
<Ref. to ABS(diag)-45, DTC C0110 ABS CONElectrical Control ModTROL MODULE MALFUNCTION, Diagnostic ule Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-52, DTC C0111 MOTOR/ Motor and Motor Relay MOTOR RELAY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-50, DTC C0114 VALVE Valve Relay RELAY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ABS(diag)-29

ABS (DIAGNOSTICS)
DTC C0115 Content of diagnosis Display ABS wheel speed sen- Abnormal ABS sor malfunction (ABS wheel speed sen- Any One of Four ABS wheel speed sensor sor on any one of Sensors Signal abnormal signal) four sensors Stop light switch circuit malfunction Brake Light Switch Reference target <Ref. to ABS(diag)-38, DTC C0115 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE OF FOUR WHEELS, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-54, DTC C0116 FAULTY STOP LIGHT SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-56, DTC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-59, DTC C0119 G SENSOR OUTPUT SIGNAL MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-40, DTC C0120 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-42, DTC C0121 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-40, DTC C0122 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-42, DTC C0123 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-40, DTC C0124 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-42, DTC C0125 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-41, DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-43, DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to ABS(diag)-49, DTC C0140 CAN COMMUNICATION MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0116
C0118
Faulty G sensor output voltage
G Sensor Failure
C0119
Abnormal G sensor output signal
G Sensor Signal
C0120
Inlet valve malfunction in hydraulic unit
Front inlet valve LH
FL Hold Valve malfunction
C0121
Outlet valve malfunction in hydraulic unit
Front outlet valve LH
FL Pressure Reducing Valve malfunction
C0122
Front inlet valve RH
FR Hold Valve malfunction
C0123
Front outlet valve RH
FR Pressure Reducing Valve malfunction
C0124
Rear inlet valve LH
RL Hold Valve malfunction
C0125
Rear outlet valve LH
RL Pressure Reducing Valve malfunction
C0126
Rear inlet valve RH
RR Hold Valve malfunction
C0127
Rear outlet valve RH
RR Pressure Reducing Valve malfunction
C0140
Defective CAN communication
Improper CAN communication
ABS(diag)-30

ABS (DIAGNOSTICS)

A: DTC C0101 ABS WHEEL SPEED SENSOR MALFUNCTION RR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE: Refer to DTC C0104 for diagnostic procedure. <Ref. to ABS(diag)-32, DTC C0104 ABS WHEEL SPEED SENSOR MALFUNCTION FL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B: DTC C0102 ABS WHEEL SPEED SENSOR MALFUNCTION RL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
C: DTC C0103 ABS WHEEL SPEED SENSOR MALFUNCTION FR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
ABS(diag)-31

ABS (DIAGNOSTICS)
D: DTC C0104 ABS WHEEL SPEED SENSOR MALFUNCTION FL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
DTC DETECTING CONDITION: Defective ABS wheel speed sensor (broken wire, input voltage too high) Defective harness connector TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
B301
ABSCM & H/U
16 1
2 17
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
5 14
6 15
B98 R2
TWISTED PAIR LINE
B15 2 1 2 1
B6 1 2
R73 1 2
TWISTED PAIR LINE
R72
E
FRONT ABS WHEEL SPEED SENSOR LH B6 B15 R72 R73 FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH
B98
B301
2 1
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
15
5 6
3 4
ABS00995
ABS(diag)-32

ABS (DIAGNOSTICS)
Step CHECK POOR CONTACT IN CONNECTOR. Check if there is poor contact between ABSCM&H/U and ABS wheel speed sensor. CHECK HARNESS CONNECTOR BETWEEN ABSCM&H/U AND ABS WHEEL SPEED SENSOR. 1) Disconnect the connector (B301) from the ABSCM&H/U. 2) Disconnect the connector from the ABS wheel speed sensor. 3) Measure the resistance between ABSCM&H/U connector and ABS wheel speed sensor connector. Connector & terminal DTC C0101 (B301) No. 3 (R72) No. 1: (B301) No. 4 (R72) No. 2: DTC C0102 (B301) No. 2 (R73) No. 1: (B301) No. 17 (R73) No. 2: DTC C0103 (B301) No. 5 (B6) No. 2: (B301) No. 6 (B6) No. 1: DTC C0104 (B301) No. 16 (B15) No. 2: (B301) No. 1 (B15) No. 1: CHECK GROUND SHORT OF HARNESS. Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal DTC C0101 (B301) No. 4 Chassis ground: DTC C0102 (B301) No. 17 Chassis ground: DTC C0103 (B301) No. 6 Chassis ground: DTC C0104 (B301) No. 1 Chassis ground: CHECK ABS WHEEL SPEED SENSOR POWER SUPPLY CIRCUIT. 1) Connect ABSCM&H/U connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between ABS wheel speed sensor connector and chassis ground. Connector & terminal DTC C0101 (R72) No. 1 (+) Chassis ground (): DTC C0102 (R73) No. 1 (+) Chassis ground (): DTC C0103 (B6) No. 2 (+) Chassis ground (): DTC C0104 (B15) No. 2 (+) Chassis ground (): Check Is there poor contact? Yes No Repair the connec- Go to step 2. tor. Repair the harness connector between ABSCM&H/U and ABS wheel speed sensor.
Go to step 4.
Repair the harness connector between ABSCM&H/U and ABS wheel speed sensor.
Go to step 6.
Go to step 5.
ABS(diag)-33

ABS (DIAGNOSTICS)
Step CHECK THE ABSCM&H/U POWER SUPPLY CIRCUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Turn the ignition switch to ON. 4) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 18 (+) (B301) No. 15 (): CHECK ABS WHEEL SPEED SENSOR SIGNAL. 1) Install the ABS wheel speed sensor. 2) Prepare an oscilloscope. 3) Check the ABS wheel speed sensor. <Ref. to ABS-14, ABS WHEEL SPEED SENSOR, INSPECTION, Front ABS Wheel Speed Sensor.> CHECK ABSCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. Check Is the voltage 10 15 V? Yes Go to step 6. No Check the generator, battery and ABSCM&H/U power supply circuit.
Is the pattern the same waveform as shown in the figure?
Go to step 7.
Replace the ABS wheel speed sensor.
CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?
Replace the ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
Go to step 8.
It results from a temporary noise interference.
E: DTC C0105 REAR ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL)
NOTE: Refer to DTC C0108 for diagnostic procedure. <Ref. to ABS(diag)-35, DTC C0108 FRONT ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC C0106 REAR ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL)
G: DTC C0107 FRONT ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL)
ABS(diag)-34

ABS (DIAGNOSTICS)
H: DTC C0108 FRONT ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL)
DTC DETECTING CONDITION: Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.) Defective harness connector TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
B301
ABSCM & H/U
16 1
2 17
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
5 14
6 15
B98 R2
TWISTED PAIR LINE
B15 2 1 2 1
B6 1 2
R73 1 2
TWISTED PAIR LINE
R72
E
B98
B301
2 1
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
15
5 6
3 4
ABS00995
ABS(diag)-35

ABS (DIAGNOSTICS)
Step CHECK OUTPUT OF ABS WHEEL SPEED SENSOR USING SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in the Subaru Select Monitor. 2) Read the output of the faulty ABS wheel speed sensor. CHECK POOR CONTACT IN CONNECTOR. Turn the ignition switch to OFF. CHECK CAUSE OF SIGNAL NOISE. Make sure the radio wave devices and electronic components are installed correctly. Check Yes Does the speed indicated on Go to step 2. the display change in response to the speedometer reading during acceleration/deceleration when the steering wheel is in the straight-ahead position? Is there poor contact in connec- Repair the connectors between ABSCM&H/U and tor. ABS wheel speed sensor? Are the radio wave devices and Go to step 4. electronic components installed correctly? No Go to step 7.
Go to step 3.
Install the noise sources apart from sensor harness. Replace the ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).> CHECK INSTALLATION OF ABS WHEEL Is the ABS wheel speed sensor Go to step 8. SPEED SENSOR. installation bolt tightened 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)? CHECK ABS WHEEL SPEED SENSOR SIGNAL. 1) Install the ABS wheel speed sensor. 2) Prepare an oscilloscope. 3) Check the ABS wheel speed sensor. <Ref. to ABS-14, ABS WHEEL SPEED SENSOR, INSPECTION, Front ABS Wheel Speed Sensor.> CHECK ABS WHEEL SPEED SENSOR OR MAGNETIC ENCODER. Does the oscilloscope indicate the waveform pattern like shown in the figure when the tire is slowly turned? Does the oscilloscope indication repeat the waveform pattern like shown in the figure when the tire is slowly turned in equal speed for one rotation or more? Are there foreign matter, breakage or damage at the tip of ABS wheel speed sensor or magnetic encoder? Go to step 10.
CHECK CAUSE OF SIGNAL NOISE. Are noise sources installed? Check if the noise sources (such as an antenna) are installed near the sensor harness. CHECK ABSCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC.
Install the radio wave devices and electronic components properly. Go to step 5.
Go to step 6.
Tighten the ABS wheel speed sensor installation bolts. Go to step 9.
10
CHECK CAUSE OF SIGNAL NOISE. Make sure the radio wave devices and electronic components are installed correctly.
Remove dirt thor- Go to step 10. oughly. Also replace the ABS wheel speed sensor or magnetic encoder as a unit with hub unit bearing if it is broken or damaged. Are the radio wave devices and Go to step 11. Install the radio electronic components wave devices and installed correctly? electronic components properly.
ABS(diag)-36

ABS (DIAGNOSTICS)
Step Check CHECK CAUSE OF SIGNAL NOISE. Is the noise sources installed? Check if the noise sources (such as an antenna) are installed near the sensor harness. CHECK ABSCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Go to step 12. No Install the noise sources apart from sensor harness. Go to step 13.
11
12
13
Replace the ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
It results from a temporary noise interference. NOTE: Though the ABS warning light remains on at this time, this is normal. Drive the vehicle at 12 km/h (7 MPH) or more in order to turn ABS warning light off. Be sure to drive the vehicle and check that the warning light goes off.
ABS(diag)-37

ABS (DIAGNOSTICS)
I:
DTC C0115 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE OF FOUR WHEELS
DTC DETECTING CONDITION: Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.) Defective magnetic encoder When a wheel is turned freely for a long time TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. NOTE: Brake warning light illuminates as well as the ABS warning light. WIRING DIAGRAM:
B301
ABSCM & H/U
16 1
2 17
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
5 14
6 15
B98 R2
TWISTED PAIR LINE
B15 2 1 2 1
B6 1 2
R73 1 2
TWISTED PAIR LINE
R72
E
B98
B301
2 1
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
15
5 6
3 4
ABS00995
ABS(diag)-38

ABS (DIAGNOSTICS)
Step Check WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely? NOT. Check if the wheels have been turned freely for one minute or more, such as when the vehicle is jacked-up, under full-lock cornering or when the wheels are not in contact with road surface. Yes No ABS is normal. Go to step 2. Clear the memory. NOTE: This diagnostic trouble code may sometimes occur if the wheels turn freely for a long time, for example when the vehicle is towed or jackedup, or when steering wheel is continuously turned all the way. Go to step 3. Replace the tire. Replace the tire. Go to step 5. Go to step 6. Go to step 4. Adjust the tire pressure. Tighten the ABS wheel speed sensor installation bolts. Go to step 7.
2 3 4 5
CHECK TIRE SPECIFICATIONS. Turn the ignition switch to OFF. CHECK WEAR OF TIRE. CHECK TIRE INFLATION PRESSURE. CHECK INSTALLATION OF ABS WHEEL SPEED SENSOR.
Are the tire specifications correct? Is the tire worn excessively? Is the tire pressure correct?
Are the ABS wheel speed sensor installation bolts tightened 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)? (For four wheels) CHECK ABS WHEEL SPEED SENSOR SIG- Does the oscilloscope indicate NAL. the waveform pattern like 1) Install the ABS wheel speed sensor. shown in the figure when the 2) Prepare an oscilloscope. tire is slowly turned? Does the 3) Check the ABS wheel speed sensor. <Ref. oscilloscope indication repeat to ABS-14, ABS WHEEL SPEED SENSOR, the waveform pattern like INSPECTION, Front ABS Wheel Speed Sen- shown in the figure when the sor.> tire is slowly turned in equal speed for one rotation or more? CHECK ABS WHEEL SPEED SENSOR OR Are there foreign matter, breakMAGNETIC ENCODER. age or damage at the tip of ABS wheel speed sensor or magnetic encoder?
Go to step 8.
CHECK ABSCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC.
Remove dirt thor- Go to step 8. oughly. Also replace the ABS wheel speed sensor or magnetic encoder as a unit with hub unit bearing if it is broken or damaged. Replace the Go to step 9. ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS(diag)-39

ABS (DIAGNOSTICS)
Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).> No It results from a temporary noise interference. NOTE: Though the ABS warning light remains on at this time, this is normal. Drive the vehicle at 12 km/h (7 MPH) or more in order to turn ABS warning light off. Be sure to drive the vehicle and check that the warning light goes off.
J: DTC C0120 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE: Refer to DTC C0126 for diagnostic procedure. <Ref. to ABS(diag)-41, DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/ U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
K: DTC C0122 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
L: DTC C0124 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS(diag)-40

ABS (DIAGNOSTICS)
M: DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
DTC DETECTING CONDITION: Defective harness connector Defective inlet solenoid valve in ABSCM&H/U TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. NOTE: Brake warning light illuminates as well as the ABS warning light. WIRING DIAGRAM:
BATTERY
MAIN SBF
SBF-6
GENERATOR
IGNITION SWITCH
No.33
E
18 15 B301 ABSCM & H/U B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS00805
ABS(diag)-41

ABS (DIAGNOSTICS)
Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 15 V? 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Run the engine at idle. 4) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 18 (+) Chassis ground (): CHECK THE ABSCM&H/U GROUND CIRIs the resistance less than 0.5 :? CUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 15 Chassis ground: CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connector between generator, battery and ABSCM&H/U? CHECK ABSCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Go to step 2. No Repair the ABSCM&H/U power circuit.
Go to step 3.
Repair the ABSCM&H/U ground harness.
Repair the connec- Go to step 4. tor. Replace the Go to step 5. ABSCM&H/U. <Ref. to ABS-6, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Check DTC using Temporary poor List of Diagnostic contact occurs. Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
N: DTC C0121 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE: Refer to DTC C0127 for diagnostic procedure. <Ref. to ABS(diag)-43, DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC C0123 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
P: DTC C0125 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS(diag)-42

ABS (DIAGNOSTICS)
Q: DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
DTC DETECTING CONDITION: Defective harness connector Defective outlet solenoid valve in ABSCM&H/U TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. NOTE: Brake warning light illuminates as well as the ABS warning light. WIRING DIAGRAM:
BATTERY
MAIN SBF
SBF-6
GENERATOR
IGNITION SWITCH
No.33
E
18 15 B301 ABSCM & H/U B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS00805
ABS(diag)-43

ABS (DIAGNOSTICS)
Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 15 V? 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Run the engine at idle. 4) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 18 (+) Chassis ground (): CHECK THE ABSCM&H/U GROUND CIRIs the resistance less than 0.5 :? CUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 15 Chassis ground: CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connector between generator, battery and ABSCM&H/U? CHECK ABSCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Go to step 2. No Repair the ABSCM&H/U power circuit.
Go to step 3.
Repair the connec- Go to step 4. tor. Replace the Go to step 5. ABSCM&H/U. <Ref. to ABS-6, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Check DTC using Temporary poor List of Diagnostic contact occurs. Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
ABS(diag)-44

ABS (DIAGNOSTICS)
R: DTC C0110 ABS CONTROL MODULE MALFUNCTION

DTC DETECTING CONDITION: Defective ABSCM&H/U TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. NOTE: Brake warning light illuminates as well as the ABS warning light. WIRING DIAGRAM:
B301
ABSCM & H/U
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
15
ABS00415
ABS(diag)-45

ABS (DIAGNOSTICS)
Step CHECK THE ABSCM&H/U GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Measure the resistance between the ABSCM&H/U and chassis ground. Connector & terminal (B301) No. 15 Chassis ground: CHECK POOR CONTACT IN CONNECTOR. Check Yes Is the resistance less than 0.5 :? Go to step 2. No Repair the ABSCM&H/U ground harness.
Is there poor contact of the con- Repair the connec- Go to step 3. nector between the battery, tor. ignition switch and ABSCM&H/ U? CHECK CAUSE OF SIGNAL NOISE. Is the car telephone or the radio Go to step 4. Properly install the properly installed? car telephone or the radio. CHECK CAUSE OF SIGNAL NOISE. Is there a noise source (such as Install the noise Go to step 5. an antenna) installed near the source apart from sensor harness? the sensor harness. CHECK ABSCM&H/U. Is the same DTC displayed? Replace the Go to step 6. 1) Connect all connectors. ABSCM only. <Ref. 2) Clear the memory. <Ref. to ABS(diag)-20, to ABS-8, Clear Memory Mode.> REPLACEMENT, 3) Perform the Inspection Mode. <Ref. to ABS Control ModABS(diag)-19, Inspection Mode.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Temporary poor List of Diagnostic contact occurs. Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
ABS(diag)-46

ABS (DIAGNOSTICS)
S: DTC C0109 POWER VOLTAGE MALFUNCTION

DTC DETECTING CONDITION: Power supply voltage of the ABSCM&H/U is too low or too high. TROUBLE SYMPTOM: ABS does not operate. EBD may not operate. NOTE: If EBD does not operate, the brake warning light illuminates in addition to ABS warning light. Both warning lights go off if voltage returns. WIRING DIAGRAM:
BATTERY
MAIN SBF
SBF-6
GENERATOR
IGNITION SWITCH
No.33
E
18 15 B301 ABSCM & H/U B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS00805
ABS(diag)-47

ABS (DIAGNOSTICS)
Step Check CHECK GENERATOR. Is the voltage 10 15 V? 1) Start the engine. 2) Run the engine at idle after warming up. 3) Measure the voltage between generator terminal B and chassis ground. Terminals Generator B terminal (+) Chassis ground (): CHECK BATTERY TERMINAL. Are the positive and negative Turn the ignition switch to OFF. battery terminals tightened securely? CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 15 V? 1) Disconnect the ABSCM&H/U connectors. 2) Run the engine at idle. 3) Operate devices such as headlights, air conditioner, defogger, etc. which produce an electrical load. 4) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 18 (+) Chassis ground (): CHECK THE ABSCM&H/U GROUND CIRIs the resistance less than 0.5 :? CUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 15 Chassis ground: CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connector between generator, battery and ABSCM&H/U? CHECK ABSCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Go to step 2. No Repair the generator.
Go to step 3.
Tighten the terminal. Repair the ABSCM&H/U power circuit.
Go to step 4.
Go to step 5.
Repair the connec- Go to step 6. tor. Replace the Go to step 7. ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Check DTC using Temporary poor List of Diagnostic contact occurs. Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
ABS(diag)-48

ABS (DIAGNOSTICS)
T: DTC C0140 CAN COMMUNICATION MALFUNCTION

DTC DETECTING CONDITION: Defective CAN communication TROUBLE SYMPTOM: Possibly the vehicle speed cannot output on CAN.
1 Step Check CHECK LAN SYSTEM. Is there any fault in LAN sysPerform the diagnosis for LAN system. <Ref. to tem? LAN(diag)-27, OPERATION, Read Diagnostic Trouble Code (DTC).> Yes No Repair it according Replace the to DTC of LAN sys- ABSCM only. <Ref. tem. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS(diag)-49

ABS (DIAGNOSTICS)
U: DTC C0114 VALVE RELAY MALFUNCTION

DTC DETECTING CONDITION: Defective valve relay TROUBLE SYMPTOM: ABS does not operate. EBD does not operate depending on the trouble contents. NOTE: Brake warning light illuminates as well as ABS warning light when EBD does not operate. WIRING DIAGRAM:
BATTERY MAIN SBF
No.1
SBF-6
IGNITION SWITCH
E
No.33 B301
14
MOTOR RELAY
18
SOLENOID VALVE FL INLET
15 PUMP MOTOR RR OUTLET FR INLET FR OUTLET RL OUTLET FL OUTLET RR INLET RL INLET
VALVE RELAY
ABSCM & H/U
B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
12
13
14
15
ABS00996
ABS(diag)-50

ABS (DIAGNOSTICS)
Step CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Run the engine at idle. 4) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 18 (+) Chassis ground (): (B301) No. 14 (+) Chassis ground (): CHECK THE ABSCM&H/U GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 15 Chassis ground: CHECK VALVE RELAY IN ABSCM&H/U. Measure the resistance between the ABSCM&H/U terminals. Terminals No. 14 No. 15: Check Is the voltage 10 15 V? Yes Go to step 2. No Repair the harness connector between battery and ABSCM&H/U.
Replace the ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connec- Repair the connec- Go to step 5. tor between generator, battery tor. and ABSCM&H/U? CHECK ABSCM&H/U. Is the same DTC displayed? Replace the Go to step 6. 1) Connect all connectors. ABSCM only. <Ref. 2) Clear the memory. <Ref. to ABS(diag)-20, to ABS-8, Clear Memory Mode.> REPLACEMENT, 3) Perform the Inspection Mode. <Ref. to ABS Control ModABS(diag)-19, Inspection Mode.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using Temporary poor List of Diagnostic contact occurs. Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
Go to step 4.
ABS(diag)-51

ABS (DIAGNOSTICS)
V: DTC C0111 MOTOR/MOTOR RELAY MALFUNCTION

DTC DETECTING CONDITION: Defective motor Defective motor relay Defective harness connector TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
BATTERY SBF-1 MAIN SBF
SBF-6
IGNITION SWITCH
15
13
MOTOR RELAY
18
SOLENOID VALVE FL INLET
VALVE RELAY
M E
ABSCM & H/U
PUMP MOTOR
RR OUTLET
FR INLET FR OUTLET
RL OUTLET
FL OUTLET
RR INLET
RL INLET
12
B301
No.33
B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
12
13
14
15
ABS00997
ABS(diag)-52

ABS (DIAGNOSTICS)
Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 15 V? 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Turn the ignition switch to ON. 4) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 13 (+) Chassis ground (): CHECK INSTALLATION OF MOTOR Is the motor ground terminal GROUND. installation bolt tightened to 33 Nm (3.3 kgf-m, 24.3 ft-lb)? CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than 0.5 :? 1) Turn the ignition switch to OFF. 2) Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 12 Chassis ground: CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 15 V? 1) Run the engine at idle. 2) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 18 (+) Chassis ground (): CHECK THE ABSCM&H/U GROUND CIRIs the resistance less than 0.5 :? CUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 15 Chassis ground: CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connecTurn the ignition switch to OFF. tor between generator, battery and ABSCM&H/U? CHECK ABSCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Yes Go to step 2. No Repair the harness connector between battery and ABSCM&H/U.
Go to step 3.
Go to step 4.
Tighten the motor ground terminal installation bolt. Repair the ABSCM&H/U ground harness.
Go to step 5.
Repair the harness connector between battery, ignition switch and ABSCM&H/U. Repair the ABSCM&H/U ground harness.
Go to step 6.
Repair the connec- Go to step 7. tor. Replace the ABSCM&H/U. <Ref. to ABS-6, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).> Go to step 8.
Temporary poor contact occurs. NOTE: Though the ABS warning light remains on at this time, this is normal. Drive the vehicle at 12 km/h (7 MPH) or more in order to turn ABS warning light off. Be sure to drive the vehicle and check that the warning light goes off.
ABS(diag)-53

ABS (DIAGNOSTICS)
W: DTC C0116 FAULTY STOP LIGHT SWITCH

DTC DETECTING CONDITION: Defective stop light switch WIRING DIAGRAM:
BATTERY
MAIN SBF
E
SBF-2 No.8
STOP LIGHT SWITCH 2 3 9 B65 B159 5 3
7.5A
FUSE (RELAY BLOCK) B225
B301
ABSCM & H/U
20
B65 1 3 2 4 1 5 2 6
B159 3 8 4 9
B301
B225 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
ABS00998
ABS(diag)-54

ABS (DIAGNOSTICS)
Step CHECK OUTPUT OF STOP LIGHT SWITCH USING SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in the Subaru Select Monitor. 2) Release the brake pedal. 3) Read the stop light switch signal in Subaru Select Monitor. CHECK OUTPUT OF STOP LIGHT SWITCH USING SUBARU SELECT MONITOR. 1) Depress the brake pedal. 2) Read the stop light switch output in Subaru Select Monitor. CHECK IF STOP LIGHTS ILLUMINATE. Depress the brake pedal. CHECK FUSE. Check the relay block fuse (B225). CHECK OPEN CIRCUIT IN HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Depress the brake pedal. 4) Measure the voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 20 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTOR. Check Is OFF displayed on the screen? Yes Go to step 2. No Go to step 3.
Is ON displayed on the screen?
Go to step 6.
Go to step 3.
3 4 5
Does the stop light illuminate? Go to step 4. Is the fuse OK? Is the voltage 10 15 V? Go to step 5. Go to step 6.
Repair the stop light circuit. Replace the fuse. Repair the harness between stop light switch and ABSCM&H/U connector.
Is there poor contact in the con- Repair the connecnector between stop light tor. switch and ABSCM&H/U? CHECK ABSCM&H/U. Is the same DTC displayed? Replace the 1) Connect all connectors. ABSCM only. <Ref. 2) Clear the memory. <Ref. to ABS(diag)-20, to ABS-8, Clear Memory Mode.> REPLACEMENT, 3) Perform the Inspection Mode. <Ref. to ABS Control ModABS(diag)-19, Inspection Mode.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
Go to step 7.
Go to step 8.
ABS(diag)-55

ABS (DIAGNOSTICS)
X: DTC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION

DTC DETECTING CONDITION: Defective G sensor TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
B301
ABSCM & H/U
24 21 10
B292 1 2 3
E
ABS G SENSOR
B292
B301
1 2 3
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
15
ABS00808
ABS(diag)-56

ABS (DIAGNOSTICS)
Step CHECK OUTPUT OF G SENSOR USING SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in the Subaru Select Monitor. 2) Read the G sensor output on Subaru Select Monitor. CHECK POOR CONTACT IN CONNECTOR. Check Yes Is the reading indicated on dis- Go to step 2. play 1.2 1.2 m/s when the G sensor is horizontal? No Go to step 5.
Is there poor contact in connec- Repair the connectors between ABSCM&H/U and tor. G sensor? CHECK ABSCM&H/U. Is the same DTC displayed? Replace the 1) Connect all connectors. ABSCM only. <Ref. 2) Clear the memory. <Ref. to ABS(diag)-20, to ABS-8, Clear Memory Mode.> REPLACEMENT, 3) Perform the Inspection Mode. <Ref. to ABS Control ModABS(diag)-19, Inspection Mode.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).> CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage 4.75 5.25 V? Go to step 6. 1) Turn the ignition switch to OFF. 2) Remove the console box. 3) Remove the G sensor from vehicle. (Do not disconnect the connector.) 4) Turn the ignition switch to ON. 5) Measure the voltage between G sensor connector terminals. Connector & terminal (B292) No. 1 (+) No. 3 (): CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance 3.6 3.8 k:? Go to step 7. PUT HARNESS AND GROUND HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Measure the resistance between ABSCM&H/U connector terminals. Connector & terminal (B301) No. 21 No. 10: CHECK GROUND SHORT IN G SENSOR Is the resistance 1 M: or Go to step 8. OUTPUT HARNESS. more? 1) Disconnect the connector from the G sensor. 2) Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 21 Chassis ground: CHECK G SENSOR. Is the voltage 2.1 2.5 V when Go to step 9. 1) Connect the connector to G sensor. G sensor is in horizontal posi2) Connect the connector to ABSCM&H/U. tion? 3) Turn the ignition switch to ON. 4) Measure the voltage between G sensor connector terminals. Connector & terminal (B292) No. 2 (+) No. 3 ():
Go to step 3.
Go to step 4.
Repair the harness connector between the G sensor and ABSCM&H/U.
Repair the harness between the G sensor and ABSCM&H/U.
Replace the G sensor. <Ref. to ABS18, G Sensor.>
ABS(diag)-57

ABS (DIAGNOSTICS)
Step CHECK G SENSOR. Measure the voltage between G sensor connector terminals. Connector & terminal (B292) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure the voltage between G sensor connector terminals. Connector & terminal (B292) No. 2 (+) No. 3 (): CHECK POOR CONTACT IN CONNECTOR. Turn the ignition switch to OFF. Check Yes Is the voltage 3.6 4.1 V when Go to step 10. the G sensor is inclined forward to 90? No Replace the G sensor. <Ref. to ABS18, G Sensor.>
10
Is the voltage 0.5 1.0 V when Go to step 11. G sensor is inclined back 90?
11
12
13
Is there poor contact in connec- Repair the connectors between ABSCM&H/U and tor. G sensor? CHECK ABSCM&H/U. Is the same DTC displayed? Replace the 1) Connect all connectors. ABSCM only. <Ref. 2) Clear the memory. <Ref. to ABS(diag)-20, to ABS-8, Clear Memory Mode.> REPLACEMENT, 3) Perform the Inspection Mode. <Ref. to ABS Control ModABS(diag)-19, Inspection Mode.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
Go to step 12.
Go to step 13.
ABS(diag)-58

ABS (DIAGNOSTICS)
Y: DTC C0119 G SENSOR OUTPUT SIGNAL MALFUNCTION

DTC DETECTING CONDITION: Defective G sensor TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
B301
ABSCM & H/U
24 21 10
B292 1 2 3
E
ABS G SENSOR
B292
B301
1 2 3
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26
15
ABS00808
ABS(diag)-59

ABS (DIAGNOSTICS)
Step Check WHETHER A WHEEL TURNED FREELY OR Have the wheels spun free of NOT. load when the vehicle is lifted up, or during driving on a rough road? CHECK OUTPUT OF G SENSOR USING Is the reading indicated on disSUBARU SELECT MONITOR. play 1.2 1.2 m/s when the G 1) Select {Current Data Display & Save} in the sensor is horizontal? Subaru Select Monitor. 2) Read the Subaru Select Monitor display. CHECK OUTPUT OF G SENSOR USING Is the value indicated on the SUBARU SELECT MONITOR. screen 8.1 11.2 m/s when G 1) Turn the ignition switch to OFF. sensor is inclined forward to 2) Remove the console box. 90? 3) Remove the G sensor from vehicle. (Do not disconnect the connector.) 4) Turn the ignition switch to ON. 5) Select {Current Data Display & Save} in the Subaru Select Monitor. 6) Read the Subaru Select Monitor display. CHECK OUTPUT OF G SENSOR USING Is the value indicated on the SUBARU SELECT MONITOR. screen 8.1 11.2 m/s when Read the Subaru Select Monitor display. G sensor is inclined backward to 90? CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connecTurn the ignition switch to OFF. tors between ABSCM&H/U and G sensor? CHECK ABSCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 4) Read the DTC. Yes No ABS is normal. Go to step 2. Clear the memory.
Go to step 3.
Go to step 8.
Go to step 4.
Go to step 5.
Repair the connec- Go to step 6. tor. Go to step 7.
Replace the ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Check DTC using List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).> CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance 3.6 3.8 k:? Go to step 9. PUT HARNESS AND GROUND HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the ABSCM&H/U connectors. 3) Measure the resistance between ABSCM&H/U connector terminals. Connector & terminal (B301) No. 21 No. 10: Go to step 10. Is the resistance 1 M: or CHECK GROUND SHORT OF HARNESS. more? Measure the resistance between the ABSCM&H/U connector and chassis ground. Connector & terminal (B301) No. 21 Chassis ground:
ABS(diag)-60

ABS (DIAGNOSTICS)
Step CHECK G SENSOR. 1) Remove the console box. 2) Remove the G sensor from vehicle. 3) Connect the connector to G sensor. 4) Connect the connector to ABSCM&H/U. 5) Turn the ignition switch to ON. 6) Measure the voltage between G sensor connector terminals. Connector & terminal (B292) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure the voltage between G sensor connector terminals. Connector & terminal (B292) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure the voltage between G sensor connector terminals. Connector & terminal (B292) No. 2 (+) No. 3 (): CHECK ABSCM&H/U. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to ABS(diag)-20, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to ABS(diag)-19, Inspection Mode.> 5) Read the DTC. CHECK FOR ANY OTHER DTC ON DISPLAY. Check Yes Is the voltage 2.1 2.5 V when Go to step 11. G sensor is in horizontal position? No Replace the G sensor. <Ref. to ABS18, G Sensor.>
10
11
Is the voltage 3.6 4.1 V when Go to step 12. the G sensor is inclined forward to 90?
12
Is the voltage 0.5 1.0 V when Go to step 13. G sensor is inclined back 90?
13
14
Replace the Go to step 14. ABSCM only. <Ref. to ABS-8, REPLACEMENT, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Check DTC using Temporary poor List of Diagnostic contact occurs. Trouble Code (DTC). <Ref. to ABS(diag)-29, List of Diagnostic Trouble Code (DTC).>
ABS(diag)-61

ABS (DIAGNOSTICS)

A: INSPECTION
Symptom Problem parts ABSCM&H/U (solenoid valve) ABS wheel speed sensor Brake (caliper, piston and pad) Wheel alignment Tire specifications, tire wear and air pressures Incorrect wiring or piping connections Road surface (uneven, camber) ABSCM&H/U (solenoid valve) ABS wheel speed sensor Brake (pad) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections ABSCM&H/U (solenoid valve) Brake (pad) Air in brake line Tire specifications, tire wear and air pressures Incorrect wiring or piping connections ABSCM&H/U (solenoid valve, motor) ABS wheel speed sensor Incorrect wiring or piping connections ABSCM&H/U (solenoid valve) ABS wheel speed sensor Master cylinder Brake (caliper and piston) Parking brake Axle & wheels Brake pedal play Air in brake line Brake pedal play Suspension play or fatigue (reduced damping) Incorrect wiring or piping connections Road surface (uneven) ABSCM&H/U (solenoid valve) ABS wheel speed sensor Brake (caliper, piston and pad) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections Road surface (uneven) Incorrect wiring or piping connections Road surface (uneven) ABSCM&H/U (mount bushing) ABS wheel speed sensor Brake line ABSCM&H/U (mount bushing) ABS wheel speed sensor Master cylinder Brake (caliper, piston, pad and rotor) Brake line Brake booster and check valve Suspension play or fatigue ABS wheel speed sensor Brake (caliper, piston, pad and rotor) Parking brake Brake line Suspension play or fatigue
Vehicle is pulled to either right or left side. Vehicle instability during braking
Vehicle spins.
Long braking/stopping distance
Wheel locks.
Brake drag Poor brake performance
Long brake pedal stroke Vehicle vertical pitching
Unstable or uneven braking
Excessive pedal vibration Noise from the ABSCM&H/U
Vibration and/or noise (while driving on slippery roads)
Noise from front of vehicle
Noise from rear of vehicle
ABS(diag)-62
General Description
VEHICLE DYNAMICS CONTROL (VDC)
A: SPECIFICATION
Item ABS wheel speed sensor gap (for reference) ABS wheel speed sensor Identifications of harness (marks, color) Front Rear Front Rear RH LH RH LH Specification or identification 0.77 1.43 mm (0.030 0.056 in) 0.64 1.56 mm (0.025 0.061 in) K1 (White) K2 (Yellow) K5 (White) K6 (Yellow) T3 T7 TA T4 TB
AT: 2.5GT SED, OBK 2.5XT, OBK 3.0R AT: 3.0R (18 inch tire) VDCCM&H/U Identification AT: OBK 2.5i, 2.5i SED, 3.0R (17 inch tire) MT: 2.5GT-B, OBK 2.5XT MT: OBK 2.5i, 2.5i SED
VDC-2
General Description
B: COMPONENT
T1
T2 T2
(3)
(5) T1 (2) (4)
(1)
T2
VDC00194
(1) (2) (3)
Front ABS wheel speed sensor Front housing Rear ABS wheel speed sensor
(4) (5)
Hub unit bearing Magnetic encoder
VDC-3
General Description
2. YAW RATE & LATERAL G SENSOR

T
(1)
(2)
VDC00447
(1)
Yaw rate & lateral G sensor
(2)
Bracket
3. STEERING ANGLE SENSOR
(1)
VDC00196
(1) Steering angle sensor
VDC-4
General Description
4. VDC CONTROL MODULE & HYDRAULIC CONTROL UNIT (VDCCM&H/U)

(3) (2) (6) (1) (4) (5) (7)
(9)
(8) T2 (10) T1 T2
T2
(11)
VDC00480
(1) (2) (3) (4) (5)
VDC control module & hydraulic control unit (VDCCM&H/U) Front RH outlet Rear LH outlet Rear RH outlet Front LH outlet
(6) (7) (8) (9) (10)
Primary inlet Secondary inlet Damper Spacer Damper
(11)
Bracket
VDC-5
General Description
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points.
D: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
2. GENERAL TOOL
TOOL NAME Circuit tester Pressure gauge Oscilloscope TORX bit E5 REMARKS Used for measuring resistance, voltage and current. Used for measuring oil pressure. Used for measuring the sensor. Used for replacing VDC control module.
VDC-6
VDC Control Module and Hydraulic Control Unit (VDCCM&H/U)

2. VDC Control Module and Hydraulic Control Unit (VDCCM&H/U)

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Use compressed air to remove moisture and dust around the VDCCM&H/U. NOTE: If the terminals become dirty, it may cause improper contact. 3) Lift the lock lever and Disconnect the VDCCM&H/U connector. CAUTION: Do not pull on the harness when disconnecting the connector.
B: INSTALLATION
1) Install the VDCCM&H/U bracket. Tightening torque: 33 Nm (3.4 kgf-m, 24 ft-lb) 2) Install the VDCCM&H/U with a new nut (Part No. 023506000) by aligning the damper groove of the VDCCM&H/U to the bracket side claw. Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
VDC00450
3) Connect the brake pipes to their correct VDCCM&H/U positions. Tightening torque: T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb) T2: 19 Nm (1.9 kgf-m, 14.0 ft-lb)
VDC00449 T1
4) Disconnect the brake pipes from the VDCCM&H/U. 5) Wrap the brake pipe with a vinyl bag so as not to spill the brake fluid on the vehicle body. CAUTION: If brake fluid is spilled on the vehicle body, wash it off immediately with water and wipe clean. 6) Remove the nuts and remove the VDCCM&H/U.
T2 VDC00451
4) Connect the VDCCM&H/U connector. NOTE: Be sure to remove all foreign matter from inside the connector before connecting. Make sure the VDCCM&H/U connector is securely locked. 5) Bleed air from the brake system. 6) Check the parameter to confirm that the applied models and grades of the relevant vehicle are included. <Ref. to VDC(diag)-17, PARAMETER CHECK, OPERATION, Subaru Select Monitor.>
VDC00450
CAUTION: Do not drop or bump the VDCCM&H/U. Do not turn the VDCCM&H/U upside down or place it sideways during storage. Be careful not to let foreign matter enter the VDCCM&H/U. Be careful that no water enters the connectors. 7) Remove the VDCCM&H/U bracket.
VDC-7

7) If the applied model and grade of the target vehicle are not included on the {Parameter Check} display screen, perform parameter selection and registration. <Ref. to VDC(diag)-16, PARAMETER SELECTION, OPERATION, Subaru Select Monitor.> NOTE: When the VDCCM&H/U is replaced with a new part, be sure to perform the selection and registration operation. For the selection and registration of parameter, the Subaru Select Monitor is required. When no data is registered, ABS/EBD/VDC warning light illuminates and the DTC Parameter selection failure is detected.
3. CHECKING THE HYDRAULIC UNIT VDC OPERATION USING A PRESSURE GAUGE

1) Lift up the vehicle, and remove the wheels. 2) Remove the air bleeder screws from FL and FR caliper bodies. 3) Connect two pressure gauges to FL and FR caliper bodies. CAUTION: Use a pressure gauge used exclusively for brake fluid measurement. Do not use a pressure gauge used for the measuring transmission oil pressure, as the piston seal may expand and deform. NOTE: Wrap sealing tape around the pressure gauge.
C: INSPECTION
1) Check the condition of connection and settlement of connector. 2) Check the mark used for VDCCM&H/U identification. Refer to SPECIFICATION for the identification mark. <Ref. to VDC-2, SPECIFICATION, General Description.>
(1)
ABS00134
VDC00452
(1) Identification mark
1. CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE

<Ref. to ABS-7, CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE, INSPECTION, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
4) Bleed air from the pressure gauge. 5) Perform VDC sequence control. <Ref. to VDC-13, VDC Sequence Control.> 6) When the hydraulic unit begins to work, first the FL side performs compression, hold, and decompression, and then the FR side performs compression, hold, and decompression. 7) Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression and compression meets specification. Depress the brake pedal and check that it is not abnormally hard, and tightness is normal.
Front wheel Rear wheel 3,000 kPa 3,000 kPa When (31 kgf/cm2, 441 psi) (31 kgf/cm2, 441 psi) pressurized or more or more 500 kPa 500 kPa When (5 kgf/cm2, 73 psi) (5 kgf/cm2, 73 psi) depressurized or less or less
2. CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH THE BRAKE TESTER
<Ref. to ABS-8, CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH THE BRAKE TESTER, INSPECTION, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
8) Disconnect the pressure gauges from FL and FR caliper bodies. 9) Install the air bleeder screws of FL and FR caliper bodies. 10) Remove the air bleeder screws from RL and RR caliper bodies. 11) Connect two pressure gauges to RL and RR caliper bodies.
VDC-8

12) Bleed air from RL and RR caliper bodies, and pressure gauge. 13) Perform VDC sequence control. <Ref. to VDC-13, VDC Sequence Control.> 14) When the hydraulic unit begins to work, first the RR side performs compression, hold, and decompression, and then the RL side performs compression, hold, and decompression. 15) Read the values indicated on the pressure gauges and check if it is within specification. Depress the brake pedal and check that it is not abnormally hard, and tightness is normal. 16) Disconnect the pressure gauge from the RL and RR caliper bodies. 17) Install the air bleeder screws of RL and RR caliper bodies. 18) Bleed air from the brake line.
6) When the hydraulic unit begins to work, check the following work sequence. (1) The FL wheel performs compression, hold and decompression in sequence, and subsequently the FR wheel repeats the cycle. (2) The RR wheel performs compression, hold and decompression in sequence, and subsequently the RL wheel repeats the cycle. 7) Read values indicated on the brake tester and check if the fluctuation of the values between decompression and compression meets specification.
Front wheel 2,000 N (203 kgf, 447 lb) or more 500 N (51 kgf, 112 lb) or less Rear wheel 2,000 N (203 kgf, 447 lb) or more 500 N (51 kgf, 112 lb) or less
When pressurized
4. CHECK HYDRAULIC UNIT VDC OPERATION WITH BRAKE TESTER

1) Set wheels other than the one to measure on free rollers. 2) Prepare to operate the VDC sequence control. <Ref. to VDC-13, VDC Sequence Control.> 3) Set the front wheels or rear wheels on the brake tester and set the select lever position to the N range.
When depressurized
8) After the inspection, depress the brake pedal and check that it is not abnormally hard, and tightness is normal.
(1) ABS00136
(1) ABS00137
(1) Brake tester
4) Operate the brake tester. 5) Perform VDC sequence control. <Ref. to VDC-13, VDC Sequence Control.>
VDC-9

D: REPLACEMENT
CAUTION: Because the pressure sensor built into the H/ U is easily damaged by static electricity, start the operation after performing static electricity measures. Be careful not to touch the sensors in the H/U to prevent damage. Because the seal of the VDCCM cannot be replaced, do not pull or peel it by lifting it up. Because the screw of the H/U will become slightly worn in every replacement procedure, 5 times is the maximum number of times for replacement. If a problem is found such as not being able to torque the screw to specifications even before 5 replacement operations are performed, replace the H/U body. When installing the VDCCM, always use new screws. When the sealing surface of the VDCCM or H/ U is dirty or damaged and it cannot be cleaned or repaired, replace with a new part. 1) Remove the VDCCM&H/U. <Ref. to VDC-7, REMOVAL, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> 2) To prevent entry of foreign objects and brake fluid leakage, plug the oil pressure port of the VDCCM&H/U using a screw plug, etc. 3) Set the pump motor section of the removed VDCCM&H/U face down on a vise. NOTE: Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise.
4) Using TORX bit E5, remove the four screws of VDCCM. NOTE: These screws cannot be reused.
ABS00431
5) Slowly pull out the VDCCM upward from the H/U. NOTE: To prevent damaging of coil section, remove the VDCCM straight up from H/U without twisting. 6) Make sure there is no dirt or damage on the sealing surface of the H/U. CAUTION: Do not clean the VDCCM&H/U by applying compressed air. Even if damage is found on the H/U seal, do not attempt repair by filing or with a metal scraper. To remove the seal residue, always use a plastic scraper. Do not use chemical such as paint thinner, etc., to clean. 7) Position the coil of the new VDCCM to align with the H/U valve. 8) To prevent deformation of the VDCCM housing cover, hold the corner of VDCCM and install it to the H/U without tilting. 9) Using a TORX bit E5, attach/tighten new screws in the order of (1) through (4). CAUTION: Always use new screws. Tightening torque: 1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
(1) (3)
(1) (2)
ABS00430
(1) Aluminum plate, etc. (2) Vise
(4)
(2) ABS00432
10) Check that there is no foreign matter in mating surface between the VDCCM&H/U.
VDC-10

11) Using a TORX bit E5, tighten the screws in the order of (1) through (4) again. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft-lb) 12) Check that there is no gap in the mating surface between VDCCM&H/U. 13) Install the VDCCM&H/U to the vehicle. 14) Bleed air from the brake system. 15) Perform the selection and registration operation of parameter. <Ref. to VDC(diag)-16, PARAMETER SELECTION, OPERATION, Subaru Select Monitor.> NOTE: After replacing the VDCCM, be sure to perform the selection and registration operation of parameter. For the selection and registration of parameter, the Subaru Select Monitor is required. When no data is registered, ABS/EBD/VDC warning light illuminates and the DTC Parameter selection error is detected. 16) Check the parameter to confirm that the applied models and grades of the relevant vehicle are included. <Ref. to VDC(diag)-17, PARAMETER CHECK, OPERATION, Subaru Select Monitor.> 17) If the applied models and grades of the relevant vehicle are not included, perform the selection and registration operation of parameter with the {Confirm Parameter} screen again. <Ref. to VDC(diag)16, PARAMETER SELECTION, OPERATION, Subaru Select Monitor.> 18) Execute Clear Memory after parameter selection and registration operations because the DTC for Parameter selection error is memorized.
E: ADJUSTMENT
When the following replacement, removal and installation are performed, be sure to perform the centering of the steering angle sensor and zero point setting of yaw rate & lateral G sensor. VDCCM&H/U Steering angle sensor Yaw rate & lateral G sensor Steering wheel parts (Including airbag) Suspension parts Wheel alignment adjustment 1) Park the vehicle straight on a level surface. (Engine operation in the P or N range) 2) Check that steering wheel is positioned at the center. (When the center position is not correct, adjust the wheel alignment.) 3) Set the Subaru Select Monitor to the vehicle, and select the {Set up mode for Neutral of Steering Angle Sensor & Lateral G Sensor 0 point} in the Function Check Sequence screen. (Follow the steps on the display.) 4) On the Brake Control System display, select the {Current Data Display & Save}, and check that the steering angle sensor shows 0 deg. 5) When the 0 deg is not displayed, repeat the above steps and check that the 0 deg is displayed. 6) Drive the vehicle for 10 minutes, and check that the ABS and VDC warning light is not illuminated. 7) Check that there is no unnecessary VDC operation or steering control loss. If there is a malfunction, repeat the steps above.
VDC-11

3. ABS Sequence Control

A: OPERATION
<Ref. to ABS-10, OPERATION, ABS Sequence Control.>
1. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

<Ref. to ABS-10, ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR, OPERATION, ABS Sequence Control.>
2. CONDITIONS FOR ABS SEQUENCE CONTROL

<Ref. to ABS-11, CONDITIONS FOR ABS SEQUENCE CONTROL, OPERATION, ABS Sequence Control.>
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL
<Ref. to ABS-12, CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL, SPECIFICATION, ABS Sequence Control.>
VDC-12
VDC Sequence Control

4. VDC Sequence Control

A: OPERATION
1) While the VDC sequence control is performed, the operation of the hydraulic unit can be checked using the brake tester or pressure gauge after the hydraulic unit solenoid valve is operated. 2) VDC sequence control can be started by Subaru Select Monitor.
1. VDC SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

NOTE: In the event of any trouble, sequence control will not operate. 1) Connect the Subaru Select Monitor to data link connector under the drivers side instrument panel lower cover. 2) Turn the ignition switch to ON. 3) Run the PC application for Subaru Select Monitor. 4) Set the Subaru Select Monitor to Brake Control mode. 5) When the VDC Inspection Mode is selected from the Function Check Sequence menu, the VDC sequence control will start. 6) Press OK will be displayed. Press the OK key. 7) Operation points will be displayed on Subaru Select Monitor.
VDC-13

2. CONDITIONS FOR VDC SEQUENCE CONTROL

V max < 4 km/h (2.5 MPH) (1) V max < 10 km/h (6 MPH)
(2)
OFF
(20)
ON (21) (22)
(24)
(25) (22)
(24)
(26) (22)
(3) (4) (5) (6) (7) (8)
(22)
(23)
(23)
(23)
VDC OFF OFF ON
(29) (25) (30) (31)
(9)
OFF (29) (25) (30) (31)
(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)
OFF OFF OFF OFF OFF OFF OFF OFF OFF ON (27) (28)
(32) (33) (34) (35) (36) VDC00275
VDC-14

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) All wheel speed Ignition key ABS warning light VDC warning light Stop light switch Valve relay VDC switching valve 1 FL VDC switching valve 1 FR VDC switching valve 2 FL VDC switching valve 2 FR FL decompression valve FL compression valve (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) FR decompression valve FR compression valve RR decompression valve RR compression valve RL decompression valve RL compression valve Pump motor 1.5 seconds Approx. 3 seconds Light OFF Light ON 3.4 seconds (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) 1 second 1.6 seconds Point A Reset 0.8 seconds 1.2 seconds 0.4 seconds Master cylinder pressure FR wheel cylinder pressure FL wheel cylinder pressure RL wheel cylinder pressure RR wheel cylinder pressure
NOTE: The control operation starts from point A.
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF VDC SEQUENCE CONTROL
When the following conditions develop, the VDC sequence control stops and VDC operation is returned to the normal control mode. 1) When the speed of at least one wheel reaches 10 km/h (6 MPH). 2) When the brake pedal is pressed during sequence control and the stop light switch is set to ON. 3) After completion of VDC sequence control. 4) When a malfunction is detected.
VDC-15
Yaw Rate and Lateral G Sensor

5. Yaw Rate and Lateral G Sensor

A: REMOVAL
1) Disconnect the ground cable from battery. 2) Remove the console box. <Ref. to EI-54, Console Box.> 3) Disconnect the connector from yaw rate & lateral G sensor. 4) Remove the yaw rate & lateral G sensor.
B: INSTALLATION
VDC00453
Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb) CAUTION: After completion of installation, set the following two positions. Positioning to the center of steering angle sensor Positioning the yaw rate & lateral G sensors to zero The above procedure is required for the VDCCM&H/U to identify the vehicle position afterward. For the setting procedures of the 2 steps above, refer to VDC Control Module and Hydraulic Control Unit (VDCCM&H/U). <Ref. to VDC-11, ADJUSTMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).>
VDC-16
Yaw Rate and Lateral G Sensor

C: INSPECTION
1. YAW RATE & LATERAL G SENSOR
1 Step CHECK YAW RATE & LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor connector to the data link connector. 3) Turn the ignition switch to ON. 4) Set the Subaru Select Monitor connector to the {Brake Control System} mode. 5) Select {Current Data Display & Save}. 6) Read the output of the yaw rate & lateral G sensor. CHECK LATERAL G SENSOR. 1) Remove the console box. 2) Remove the yaw rate & lateral G sensors from vehicle. (Do not disconnect the connector.) 3) Read the display of Subaru Select Monitor. NOTE: When the yaw rate & lateral G sensor is moved with its power supply on, DTC of yaw rate & lateral G sensor may be recorded. CHECK LATERAL G SENSOR. Read the display of Subaru Select Monitor. NOTE: When the yaw rate & lateral G sensor is moved with its power supply on, DTC of yaw rate & lateral G sensor may be recorded. Check Yes Are the indicated values as fol- Go to step 2. lows when the vehicle is placed horizontally? Lateral G sensor: 1.5 1.5 m/s, Yaw rate sensor: 4 4 deg/s No Repair the harness connector between yaw rate & lateral G sensor and VDCCM&H/U. Or replace the yaw rate & lateral G sensor.
Is the value 6.8 12.8 m/s when the yaw rate & lateral G sensor is inclined 90 to the right?
Go to step 3.
Repair the harness connector between yaw rate & lateral G sensor and VDCCM&H/U. Or replace the yaw rate & lateral G sensor.
Is the value 6.8 12.8 m/s when the yaw rate & lateral G sensor is inclined 90 to the right?
Yaw rate & lateral Repair the harness G sensors are nor- connector between mal. yaw rate & lateral G sensor and VDCCM&H/U. Or replace the yaw rate & lateral G sensor.
VDC-17
Steering Angle Sensor

6. Steering Angle Sensor

A: REPLACEMENT
CAUTION: Do not perform the removal except when the replacement. When replacing three times or more, replace the combination switch as assembly to protect the threads. 1) Set the steering wheel in a straight-ahead position. 2) Disconnect the ground cable from battery. 3) Remove the airbag module. <Ref. to AB-14, REMOVAL, Drivers Airbag Module.> WARNING: Always refer to Airbag System when performing the airbag module repair service. <Ref. to AB-4, CAUTION, General Description.> 4) Remove the steering wheel. <Ref. to PS-13, REMOVAL, Steering Wheel.> 5) Remove the screws and remove the steering column lower cover. 6) Remove the two screws securing the steering column upper cover. 7) Disconnect the connector of paddle shift assembly. (Model with paddle shift)
8) Remove the paddle shift assembly. (Model with paddle shift)
CS-00729
9) Disconnect the connector of roll connector and steering angle sensor. 10) Remove the screws which secure the roll connector to steering column.
CS-00728
VDC00207
11) Remove the vinyl tape binding the harness, and remove the steering angle sensor from roll connector.
VDC00208
VDC-18
Steering Angle Sensor

12) Turn the protrusion portion of new steering angle sensor to match the alignment mark of inspection hole.
16) Install the roll connector to combination switch and bind the harness with vinyl tape as originally bound.
(1) (2) (3)
VDC00209
VDC00207
(1) Protrusion portion (2) Inspection hole (3) Alignment mark
17) Install the paddle shift. (Model with paddle shift) 18) Install the steering wheel. <Ref. to PS-13, INSTALLATION, Steering Wheel.> Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) 19) Install the airbag module to the steering wheel. <Ref. to AB-14, INSTALLATION, Drivers Airbag Module.> WARNING: Always refer to Airbag System before performing the service operation. <Ref. to AB-4, CAUTION, General Description.> 20) Connect the ground cable to battery. CAUTION: After completion of installation, adjust the following two positions. Positioning to the center of steering angle sensor Positioning the yaw rate & lateral G sensors to zero The above procedure is required for the VDCCM to identify vehicle position afterward. For the setting procedures of the 2 steps above, refer to VDC Control Module and Hydraulic Control Unit (VDCCM&H/U). <Ref. to VDC-11, ADJUSTMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).>
CAUTION: Be careful not to allow foreign matter to enter into inspection hole. 13) Align the center of roll connector. <Ref. to AB-25, INSTALLATION, Roll Connector.> 14) Apply the grease provided with the new part on the four locations of the protrusion on the steering angle sensor.
(1)
ABS00435
(1) Grease application location
15) Align the position of the protrusion and install roll connector to steering angle sensor. Tightening torque: 0.5 Nm (0.05 kgf-m, 0.36 ft-lb)
VDC00208
VDC-19

7. Front ABS Wheel Speed Sensor

A: NOTE
Vehicles equipped with VDC have the same ABS wheel speed sensor as installed on vehicles equipped with ABS. Refer to Front ABS Wheel Speed Sensor for removal, installation and inspection procedures. <Ref. to ABS-13, Front ABS Wheel Speed Sensor.>
VDC-20
Rear ABS Wheel Speed Sensor

8. Rear ABS Wheel Speed Sensor

A: NOTE
Vehicles equipped with VDC have the same ABS wheel speed sensor as installed on vehicles equipped with ABS. Refer to Rear ABS Wheel Speed Sensor for removal, installation and inspection procedures. <Ref. to ABS-15, Rear ABS Wheel Speed Sensor.>
VDC-21
Front Magnetic Encoder

9. Front Magnetic Encoder

A: NOTE
Vehicles equipped with VDC have the same magnetic encoder as installed on vehicles equipped with ABS. Refer to Front Magnetic Encoder for removal, installation and inspection procedures. <Ref. to ABS-16, Front Magnetic Encoder.>
VDC-22
Rear Magnetic Encoder

10.Rear Magnetic Encoder

A: NOTE
Vehicles equipped with VDC have the same magnetic encoder as installed on vehicles equipped with ABS. Refer to Rear Magnetic Encoder for removal, installation and inspection procedures. <Ref. to ABS-17, Rear Magnetic Encoder.>
VDC-23
VDC OFF Switch

11.VDC OFF Switch

A: REMOVAL
1) Remove the instrument panel lower cover. 2) Remove the screws, and then remove the VDC OFF switch.
7 6 5 4 3 2 1 15 14 13 12 11 10 9 8
VDC00240
B: INSTALLATION
C: INSPECTION
Measure the resistance between the VDC OFF switch terminals.
Switch position OFF ON Terminal No. 5 15 5 15 Standard 1 M: or more Less than 1 :
If NG, replace the VDC OFF switch.
VDC-24

VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS)

A: PROCEDURE
CAUTION: Remove foreign matter (dust, water, oil etc.) from the VDCCM&H/U connector during removal and installation. NOTE: To check the harness for open or short circuits, shake problem spot or connector. Refer to Check List for Interview. <Ref. to VDC(diag)-4, Check List for Interview.>
1 Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to VDC(diag)-4, Check List for Interview.> 2) Before performing diagnostics, check the component which might affect VDC problems. <Ref. to VDC(diag)-8, INSPECTION, General Description.> CHECK INDICATION OF DTC. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON and run the Subaru Select Monitor. 4) Read the DTC using the Subaru Select Monitor. <Ref. to VDC(diag)-21, OPERATION, Read Diagnostic Trouble Code (DTC).> NOTE: If the communication function of the Subaru Select Monitor cannot be executed normally, check the communication circuit. <Ref. to VDC(diag)-18, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.> 5) Record all DTCs and freeze frame data. PERFORM GENERAL DIAGNOSTICS. 1) Perform the inspection by referring to General Diagnostic Table. <Ref. to VDC(diag)-101, INSPECTION, General Diagnostic Table.> 2) Perform the Clear Memory Mode. <Ref. to VDC(diag)-23, OPERATION, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, PROCEDURE, Inspection Mode.> 4) Read the DTC. <Ref. to VDC(diag)-21, OPERATION, Read Diagnostic Trouble Code (DTC).> 5) Check the DTC is not displayed. Check Yes Is the component that might Go to step 2. influence the VDC problem normal? No Repair or replace each component.
Is DTC displayed on the Subaru Go to step 4. Select Monitor?
Go to step 3.
Do the VDC warning light and ABS warning light go off after starting the engine?
Finish the diagno- Check the combisis. nation meter circuit. <Ref. to VDC(diag)-29, ABS WARNING LIGHT DOES NOT GO OFF, Warning Light Illumination Pattern.> <Ref. to VDC(diag)-31, VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT DO NOT GO OFF, Warning Light Illumination Pattern.>
VDC(diag)-2

Step Check PERFORM DIAGNOSIS. Is DTC displayed? 1) Refer to List of Diagnostic Trouble Code (DTC). NOTE: For the DTC list, refer to List of Diagnostic Trouble Code (DTC). <Ref. to VDC(diag)-34, LIST, List of Diagnostic Trouble Code (DTC).> 2) Correct the cause of trouble. 3) Perform the Clear Memory Mode. <Ref. to VDC(diag)-23, OPERATION, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, PROCEDURE, Inspection Mode.> 5) Read the DTC. <Ref. to VDC(diag)-21, OPERATION, Read Diagnostic Trouble Code (DTC).> Yes No Repeat step 4 until Finish the diagnoDTC is not shown. sis.
VDC(diag)-3


A: CHECK
Check the following item about the vehicles state.
1. STATE OF ABS WARNING LIGHT

ABS warning light illuminates. Always Sometimes Only once Does not come on When/How long does it illuminate? LOCK ACC ON (before starting engine) START ON (after starting engine, engine is running) ON (after starting engine, engine is at a standstill) Immediately after turning the ignition switch to ON Immediately after turning the ignition switch to START While accelerating While driving at a constant speed While decelerating When turning to the right When turning to the left When other electrical parts are operating Part name: Operating condition: Steering angle: Steering time: Steering angle: Steering time:
Timing
km/h
VDC(diag)-4

2. STATE OF VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT

VDC warning light and VDC OFF indicator light illuminate. Always Sometimes Only once Does not come on When/How long does it illuminate? LOCK ACC ON (before starting engine) START ON (after starting engine, engine is running) ON (after starting engine, engine is at a standstill) Immediately after turning the ignition switch to ON Immediately after turning the ignition switch to START While accelerating While driving at a constant speed While decelerating When turning to the right When turning to the left When other electrical parts are operating Part name: Operating condition: Steering angle: Steering time: Steering angle: Steering time:
Timing
km/h
3. STATE OF VDC INDICATOR LIGHT

VDC operation indicator light illuminate. Always Sometimes Only once Does not come on When/How long does it illuminate? LOCK ACC ON (before starting engine) START ON (after starting engine, engine is running) ON (after starting engine, engine is at a standstill) Immediately after turning the ignition switch to ON Immediately after turning the ignition switch to START While accelerating While driving at a constant speed While decelerating When turning to the right When turning to the left When other electrical parts are operating Part name: Operating condition: Steering angle: Steering time: Steering angle: Steering time:
Timing
km/h
VDC(diag)-5

4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment a) Weather Fine Cloudy Rainy Snowy Others: C (F) Inner city Suburbs Highway Local street Uphill Downhill Paved road Gravel road Muddy road Sandy place Straight road Sharp curve Gentle curve S-curve Road with a slope on both sides Others: Dry Wet Covered with fresh snow Covered with hardened snow Frozen slope Others:
b) Ambient temperature c) Road
d) Road surface
VDC(diag)-6

Condition a) Brakes b) Accelerator c) Vehicle speed Deceleration: Continuous / Acceleration: Continuous / G Intermittent G Intermittent km/h MPH
d) Tire inflation pressure
e) Degree of wear
f) Steering wheel
g) Tire/Wheel size h) Tire variation i) Tire chain is attached: Yes / No j) T-type tire is used: Yes / No k) Condition of suspension alignment: l) Loading state: m) Repair parts are used: Contents: n) Others: Yes / No
Advancing While accelerating While decelerating At low speed When turning Others: Front RH tire: Front LH tire: Rear RH tire: Rear LH tire: Front RH tire: Front LH tire: Rear RH tire: Rear LH tire: Sharp turning Gentle turning Straight forward motion Gentle return Sharp return Specified size Except specification ( Summer tire Studless tire (Brand:
kPa kPa kPa kPa
) )
VDC(diag)-7
General Description
A: CAUTION
Airbag system wiring harness is routed near the ABS wheel speed sensor and VDCCM&H/U. CAUTION: All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage the airbag system wiring harness when servicing the ABS wheel speed sensor and VDCCM&H/U.
3. BRAKE FLUID
1) Check the brake fluid level. 2) Check the brake fluid for leaks.
4. HYDRAULIC UNIT
Check the hydraulic unit. With brake tester <Ref. to VDC-8, CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH THE BRAKE TESTER, INSPECTION, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Without brake tester <Ref. to VDC-8, CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE, INSPECTION, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).>
B: INSPECTION
Before performing diagnosis, check the following items which might affect VDC problems.
5. BRAKE DRAG
Check for brake drag.
1. BATTERY
Measure the battery voltage and check electrolyte. Standard voltage: 12 V or more Specific gravity: 1.260 or more
6. BRAKE PAD AND ROTOR

Check the brake pad and rotor. Front <Ref. to BR-13, INSPECTION, Front Brake Pad.> <Ref. to BR-14, INSPECTION, Front Disc Rotor.> Rear <Ref. to BR-19, INSPECTION, Rear Brake Pad.> <Ref. to BR-21, INSPECTION, Rear Disc Rotor.>
2. GROUND
Check the tightening torque of ground (GB-7) bolt of VDC. Tightening torque: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
7. TIRE
Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATION, General Description.>
C: PREPARATION TOOL
1. SPECIAL TOOL
ST1B022XU0
2. GENERAL TOOL
VDC(diag)-8


A: LOCATION
(8) (7) (4) (5) (6)
(9)
(3)
(2) (1)
(12) (13)
(11)
(10)
(14) (15)
(11)
(10)
VDC00469
(1) (2) (3) (4)
VDC control module and hydraulic control unit (VDCCM&H/U) Connector Transmission control module (TCM) Brake warning light (EBD warning light)
(5) (6) (7) (8) (9)
ABS warning light VDC indicator light VDC warning light and VDC OFF indicator light Steering angle sensor VDC OFF switch
(10) (11) (12) (13) (14) (15)
Magnetic encoder ABS wheel speed sensor Yaw rate & lateral G sensor Data link connector Engine control module (ECM) Stop light switch
VDC(diag)-9

(1)
(4)
(5)
(7) VDC00455 (8) (11) (10)
(6) VDC00656
VDC00235
(10)
VDC00234
(13) (12)
VDC00456
VDC00242
VDC(diag)-10


B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00457
NOTE: Terminal numbers in VDCCM&H/U connector are shown in the figure. When the connector is removed from VDCCM&H/U, the ABS warning light, VDC warning light and VDC OFF indicator light illuminate.
VDC(diag)-11

Terminal No. (+) () 28 25 26 25 1 5 25 6 2 25 27 3 25 4 35 10 24 25 23 22 32 25 8 25 30 25 7 25 33 25 Input/Output signal Measured value and measuring conditions 10 15 V when the ignition switch is ON. 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 4.5 16.5 V 5.9 16.8 mA: Rectangle waveform 2.5 1.5 V pulse signal 3.5 2.5 V pulse signal 10 15 V when the ignition switch is ON. 10 15 V when the ignition switch is ON. After turning the ignition switch to ON, 10 15 V during 1.5 seconds, and 1.5 V or less after 1.5 seconds passed. After turning the ignition switch to ON, 10 15 V during 1.5 seconds, and 1.5 V or less after 1.5 seconds passed. 1.5 V or less when the stop light is OFF; otherwise, 10 15 V when the stop light is ON. 0 mo 12 V pulse (in communication) 0 mo 12 V pulse
Content Power supply Power supply Signal Power supply Front RH wheel Signal ABS wheel speed sensor Power supply Rear LH wheel Signal Power supply Rear RH wheel Signal CAN communication line (+) CAN communication line () Valve relay power supply Motor relay power supply Front LH wheel ABS warning light Brake warning light (EBD warning light) Stop light switch Subaru Select Monitor Vehicle speed output signal Ground
VDC(diag)-12

B: WIRING DIAGRAM
(3)
(20) (1) (21) (22) (23) (2) (24) (25) (26) (6)
(5)
(36)
(4) (29) (30) (31) (32) (33) (34) (35) (27) (28)
M
(8) (9) (10) (11) (12) (13) (14) (37) (38) (39) (40) (15) (16) (17) (18) (19)
(7)
VDC00458
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Battery Ignition switch VDC control module and hydraulic control unit (VDCCM&H/U) VDC control module Valve relay Motor relay Motor Front inlet solenoid valve LH Front outlet solenoid valve LH Front inlet solenoid valve RH Front outlet solenoid valve RH Rear inlet solenoid valve LH Rear outlet solenoid valve LH
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)
Rear inlet solenoid valve RH Rear outlet solenoid valve RH Primary cut solenoid valve Primary suction solenoid valve Secondary cut solenoid valve Secondary suction solenoid valve Data link connector VDC OFF switch Combination meter VDC indicator light VDC warning light and VDC OFF indicator light ABS warning light Brake warning light
(27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40)
Parking brake switch Brake fluid level switch Stop light switch Stop light Body integrated unit Engine control module (ECM) Transmission control module (TCM) Steering angle sensor Yaw rate & lateral G sensor Pressure sensor Front ABS wheel speed sensor LH Front ABS wheel speed sensor RH Rear ABS wheel speed sensor LH Rear ABS wheel speed sensor RH
VDC(diag)-13


A: OPERATION
1. HOW TO USE SUBARU SELECT MONITOR
1) Prepare the Subaru Select Monitor kit. <Ref. to VDC(diag)-8, SPECIAL TOOL, PREPARATION TOOL, General Description.>
8) If VDC and Subaru Select Monitor cannot communicate, check the communication circuit. <Ref. to VDC(diag)-18, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.>
EN-05692
(1)
ABS00465
CAUTION: Do not connect scan tools other than the Subaru Select Monitor. 6) Start the PC. 7) Turn the ignition switch to ON (engine OFF) and run the PC application for Subaru Select Monitor. NOTE: For detailed operation procedure, refer to the PC application help for Subaru Select Monitor.
VDC(diag)-14


1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Brake Control System}. 3) Click the [OK] button after the {VDC} is displayed. 4) On the Brake Control Diagnosis display, select the {Current Data Display & Save}. 5) On the Data Display Menu display, select the data display method. 6) Using the scroll key, scroll the display screen up or down until necessary data is shown. A list of the support data is shown in the following table.
Display FR Wheel Speed FL Wheel Speed RR Wheel Speed RL Wheel Speed Steering Angle Sensor Op Yaw Rate Sensor Output Pressure Sensor Output Lateral G Sensor output ABS_CM Power Voltage E/G Control Stop Flag ABS Control Flag EBD Control Flag TCS Control Flag VDC Control Flag OFF Lamp EBD Warning Light ABS Warning Light VDC Warning Light Valve Relay Signal Motor Relay Signal M. Relay monitor Voltage OFF SW Signal Brake Switch Contents to be displayed Wheel speed detected by front ABS wheel speed sensor RH is displayed. Wheel speed detected by front ABS wheel speed sensor LH is displayed. Wheel speed detected by rear ABS wheel speed sensor RH is displayed. Wheel speed detected by rear ABS wheel speed sensor LH is displayed. Steering angle detected by steering angle sensor is displayed. Vehicle angular speed detected by yaw rate sensor is displayed. Brake fluid pressure detected by pressure sensor is displayed. Vehicle lateral acceleration detected by lateral G sensor is displayed. Voltage supplied to VDCCM&H/U is displayed. Engine control command signal is displayed. ABS operation condition is displayed. EBD operation condition is displayed. TCS operation condition is displayed. VDC operation condition is displayed. ON/OFF condition of VDC OFF indicator light is displayed. ON operation of the EBD warning light is displayed. ON operation of the ABS warning light is displayed. ON operation of the VDC warning light is displayed. Valve relay operation signal is displayed. Motor relay operation signal is displayed. Voltage applied to the motor relay is displayed. Operation condition of VDC OFF switch is displayed. Brake ON/OFF is displayed. Unit of measure km/h or MPH km/h or MPH km/h or MPH km/h or MPH deg deg/s bar m/s (m/s2) V 1 or 0 ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF V ON or OFF ON or OFF
NOTE: For detailed operation procedure, refer to the PC application help for Subaru Select Monitor.
3. FUNCTION CHECK
Display ABS Sequence Control Mode VDC Check Mode Set mode Str. A.Sen.N&Lat.GSen.0p Contents of display Operate the valve and pump motor continuously to perform the ABS sequence control. Operate the valve and pump motor continuously to perform the VDC sequence control. Set the steering angle sensor neutral position and the lateral G sensor 0 point. Index No. <Ref. to ABS-10, ABS Sequence Control.> <Ref. to VDC-13, VDC Sequence Control.> <Ref. to VDC-18, Steering Angle Sensor.>
VDC(diag)-15

4. FREEZE FRAME DATA

NOTE: Data stored at the time of trouble occurrence is shown on display. Each time a trouble occurs, the latest information is stored in the freeze frame data in memory. If a freeze frame data is not properly stored in memory (due to a drop in VDCCM power supply, etc.), a DTC suffixed with a question mark ? will appear on the Subaru Select Monitor display. This shows it may be an unreliable reading.
Display Steering Angle Sensor Op Yaw Rate Sensor Output Lateral G Sensor output Pressure Sensor Output Vehicle Speed FR Wheel Speed Contents to be displayed Steering angle detected by steering angle sensor is displayed. Vehicle angular speed detected by yaw rate sensor is displayed. Vehicle lateral acceleration detected by lateral G sensor is displayed. Brake fluid pressure detected by pressure sensor is displayed. Vehicle speed calculated by VDC control module is displayed. Wheel speed detected by front ABS wheel speed sensor RH is displayed in km/h or MPH. Wheel speed detected by front ABS wheel speed sensor LH is displayed in km/h or MPH. Wheel speed detected by rear ABS wheel speed sensor RH is displayed in km/h or MPH. Wheel speed detected by rear ABS wheel speed sensor LH is displayed in km/h or MPH. Acceleration opening is displayed.
5. PARAMETER SELECTION
CAUTION: Subaru Select Monitor is required for parameter selection. This function can be used for the replacement VDCCM&H/U and VDCCM. NOTE: When a VDCCM is replaced with a replacement, use this function to select and register parameters to the VDCCM. For confirmation of applied models, refer to the Model number plate attached to the vehicles. <Ref. to ID-2, IDENTIFICATION, Identification.> If a wrong applied model is written, it can be rewritten. When no data is registered, ABS/EBD/VDC warning light illuminates and the DTC Parameter selection error is detected. 1) Connect the Subaru Select Monitor. 2) On the Main Menu display, select the {Each System Check}. 3) On the System Selection Menu display, select the {Brake Control System}. 4) Click the [OK] button after the {VDC} is displayed. 5) On the Brake Control Diagnosis display, select the {Selection of Parameter}. 6) Check the applied model indicated in the Model number plate. <Ref. to ID-2, IDENTIFICATION, Identification.> 7) Enter the applied model of 7-digit alphanumeric characters and press the [Enter] key. 8) When the confirmation screen indicating the vehicle information appears, check that the correct applied model and grade are displayed and click the [OK] button. NOTE: When the displayed applied model and grade are different from those of the vehicle, perform registration operations again after clicking the [OK] button. 9) Execute Clear Memory after parameter selection and registration operations because the DTC for Parameter selection error is memorized.
FL Wheel Speed
RR Wheel Speed
RL Wheel Speed Accel. Opening Angle Engine Speed
Engine speed on malfunction occurrence is displayed. Gear position on malfunction occurGear Position rence is displayed. ABS_CM Power Voltage supplied to VDC control module Voltage is displayed. Whether the absolute angle of the Steering angle steering angle sensor was determined flag is displayed. E/G Control Stop Engine control command signal is disFlag played. VDC Control Flag VDC control condition is displayed. EBD Control Flag EBD control condition is displayed. TCS Control Flag TCS control condition is displayed. ABS Control Flag ABS control condition is displayed. OFF Switch ON/OFF condition of the VDC operated Detection by the driver is displayed. Brake Switch Brake ON/OFF is displayed.
VDC(diag)-16

6. PARAMETER CHECK
NOTE: The parameter data registered in the VDCCM is shown on the display. 1) Connect the Subaru Select Monitor. 2) On the Main Menu display, select the {Each System Check}. 3) On the System Selection Menu display, select the {Brake Control System}. 4) Click the [OK] button after the {VDC} is displayed. 5) On the Brake Control Diagnosis display, select the {Confirm on parameter}. 6) On the {Confirm on parameter} display screen, check that the applied model and grade of the target vehicle are included, and click the [OK] button. 7) If the applied model and grade of the target vehicle are not included on the {Confirm on parameter} display screen, perform parameter selection and registration. <Ref. to VDC(diag)-16, PARAMETER SELECTION, OPERATION, Subaru Select Monitor.>
VDC(diag)-17

B: INSPECTION
DETECTING CONDITION: Defective harness connector TROUBLE SYMPTOM: Communication is impossible between VDC and Subaru Select Monitor. WIRING DIAGRAM:
BATTERY
MAIN SBF
SBF-6
M/B No.13
IGNITION SWITCH
DATA LINK CONNECTOR 16 7 B40
F/B No.33
E
28 25 B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 7 B310 VDCCM & H/U
B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
VDC00498
VDC(diag)-18

Step CHECK IGNITION SWITCH. Check Is the ignition switch ON? Yes Go to step 2. No Turn the ignition switch to ON, and select VDC mode using Subaru Select Monitor. Charge or replace the battery. Go to step 4.
10
Is there poor contact at the bat- Repair or tighten tery terminal? the battery terminal. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Go to step 8. MUNICATION. on Subaru Select Monitor? 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to other systems can be executed normally. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Replace the MUNICATION. on Subaru Select Monitor? VDCCM only. 1) Turn the ignition switch to OFF. <Ref. to VDC-10, 2) Disconnect the VDCCM&H/U connector. REPLACEMENT, 3) Turn the ignition switch to ON. VDC Control Mod4) Check whether communication to other sysule and Hydraulic tems can be executed normally. Control Unit (VDCCM&H/U).> CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M: or Go to step 7. EACH CONTROL MODULE AND DATA LINK more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the VDCCM&H/U, ECM and TCM. 3) Measure the resistance between data link connector and chassis ground. Connector & terminal (B40) No. 7 Chassis ground: CHECK OUTPUT SIGNAL FOR VDCCM&H/U. Is the voltage less than 1 V? Go to step 8. 1) Turn the ignition switch to ON. 2) Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 7 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 :? Go to step 9. VDCCM&H/U AND DATA LINK CONNECTOR. Measure the resistance between VDCCM&H/U connector and data link connector. Connector & terminal (B310) No. 7 (B40) No. 7: Is the VDCCM&H/U connector Go to step 10. CHECK INSTALLATION OF VDCCM&H/U inserted into VDCCM&H/U until CONNECTOR. Turn the ignition switch to OFF. the clamp locks onto it? CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 15 V? Go to step 11. 1) Turn the ignition switch to ON. (engine OFF) 2) Measure the ignition power supply voltage between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 28 (+) Chassis ground ():
CHECK BATTERY. 1) Turn the ignition switch to OFF. 2) Measure the battery voltage. CHECK BATTERY TERMINAL.
Go to step 3.
Go to step 5.
Go to step 6.
Repair the harness and connector between each control module and data link connector. Repair harness and connector between VDCCM&H/U and data link connector. Insert VDCCM&H/ U connector into VDCCM&H/U. Repair open circuit in harness between VDCCM&H/U and battery.
VDC(diag)-19

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 :? Go to step 12. VDCCM&H/U AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the VDCCM&H/U. 3) Measure the resistance of harness between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 25 Chassis ground: CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in control Repair the connecmodule power supply, ground tor. circuit and data link connector? No Repair the open circuit of VDCCM&H/U ground harness and poor contact of connector.
11
12
Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).>
VDC(diag)-20


A: OPERATION
1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Brake Control System}. 3) Click the [OK] button after the {VDC} is displayed. 4) On the Brake Control Diagnosis display, select the {Diagnostic Code(s) Display}. 5) Record the DTC and data. NOTE: For detailed operation procedure, refer to the PC application help for Subaru Select Monitor. For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).> Up to 3 DTCs are displayed in the order of detection. If a particular DTC is not stored in memory properly at the occurrence of problem (due to a drop in VDCCM&H/U power supply etc.), the DTC suffixed with a question mark ? is displayed on Subaru Select Monitor display screen. This shows it may be an unreliable reading.
Display (Current) (Old) Contents to be displayed The current DTC is displayed on Subaru Select Monitor display screen. The latest DTC in previous troubles is displayed on Subaru Select Monitor display screen. The second latest DTC in previous troubles is displayed on Subaru Select Monitor display screen. The third latest DTC in previous troubles is displayed on Subaru Select Monitor display screen.
(Older)
(Before 3)
VDC(diag)-21
Inspection Mode
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition as much as possible. Drive the vehicle at least ten minutes. NOTE: Make sure the vehicle is not dragged to one side under usual driving condition.
VDC(diag)-22
Clear Memory Mode


A: OPERATION
1) On the Main Menu display, select the {Each System Check}. 2) On the System Selection Menu display, select the {Brake Control System}. 3) Click the [OK] button after the {VDC} is displayed. 4) On the Brake Control Diagnosis display, select the {Clearing Memory}. 5) When the Clear Memory? is shown on the screen, click the [Yes] button. 6) When Done and Turn off the ignition switch. are shown on the display screen, turn the ignition switch to OFF. NOTE: For detailed operation procedure, refer to the PC application help for Subaru Select Monitor.
VDC(diag)-23
Warning Light Illumination Pattern

10.Warning Light Illumination Pattern

A: INSPECTION
(4) (3) (1) (2) (3)
(7) (5) (6) (8) (6)
(7) (9) (6) (6)
(7) (10) (6) (11) (7) (12) (13) (6) (6)
(14) VDC00214
(1) (2) (3) (4) (5) (6) (7)
Ignition switch OFF ON Engine start ABS warning light Light OFF Light ON
(8) (9) (10) (11)
2 seconds VDC indicator light VDC warning light and VDC OFF indicator light Several seconds (depending on engine coolant temperature)
(12) (13) (14)
Brake warning light (EBD warning light) Parking brake Released
VDC(diag)-24

1) When warning lights or indicator lights do not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2) When warning lights or indicator lights remain constantly OFF, check the combination meter circuit or CAN communication circuit. <Ref. to VDC(diag)-26, VDC WARNING LIGHT, VDC OFF INDICATOR LIGHT AND VDC INDICATOR LIGHT DO NOT COME ON, Warning Light Illumination Pattern.> 3) When ABS warning light does not go off, check the combination meter circuit. <Ref. to VDC(diag)29, ABS WARNING LIGHT DOES NOT GO OFF, Warning Light Illumination Pattern.> 4) When the VDC indicator light, VDC warning light and VDC OFF indicator light do not go off, check the combination meter circuit or CAN communication circuit. <Ref. to VDC(diag)-30, VDC INDICATOR LIGHT DOES NOT GO OFF, Warning Light Illumination Pattern.> <Ref. to VDC(diag)-31, VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT DO NOT GO OFF, Warning Light Illumination Pattern.> NOTE: Even though the ABS warning light does not go off after 2 seconds from ABS warning light illumination, the ABS system operates normally when the warning light goes off while driving at approximately 12 km/h (7 MPH). However, the ABS system does not work while the ABS warning light is illuminated. It may take several minutes before VDC warning light and VDC OFF indicator light goes off if the vehicle is parked under low temperature for a specified time. This is not defective because it is resulted from low engine coolant temperature. With the vehicle jack-up/lift-up or set on free rollers, when the wheels lock or spin after starting the engine, ABS warning light, VDC warning light and VDC OFF indicator light may illuminate because VDCCM&H/U detects the abnormal conditions from ABS wheel speed sensors. In this case, this is not a malfunction. Perform the Clear Memory Mode.
VDC(diag)-25

B: VDC WARNING LIGHT, VDC OFF INDICATOR LIGHT AND VDC INDICATOR LIGHT DO NOT COME ON
DETECTING CONDITION: Defective combination meter Defective CAN communication TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), VDC indicator light, VDC warning light and VDC OFF indicator light do not illuminate. NOTE: When pressing the VDC OFF switch for 10 seconds or more, the VDC OFF indicator light goes off and cannot operate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status is restored.
1 Step CHECK OTHER INDICATOR LIGHT. Turn the ignition switch to ON. CHECK VDCCM. When the engine does not start, display the current data of VDCCM using Subaru Select Monitor. CHECK LAN SYSTEM. Perform the diagnosis for LAN system. <Ref. to LAN(diag)-27, OPERATION, Read Diagnostic Trouble Code (DTC).> CHECK COMBINATION METER. Check the combination meter. Check Yes Does other indicator light illumi- Go to step 2. nate soon after ON. Is VDC Warning Light output Go to step 3. set to ON? No Perform the selfdiagnosis of combination meter. Replace the VDCCM only.
Is there any fault in LAN system?
Is combination meter OK?
Perform the diag- Go to step 4. nosis according to DTC for LAN system. Replace the Repair the combiVDCCM only. nation meter assembly.
VDC(diag)-26

C: ABS WARNING LIGHT DOES NOT COME ON

DETECTING CONDITION: Defective combination meter Defective harness TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), ABS warning light does not illuminate. WIRING DIAGRAM:
BATTERY MAIN SBF
SBF-6
E
No.33
BRAKE WARNING LIGHT
: NORMAL METER : A5 METER WITH MID : B5
REVERSE CIRCUIT
REVERSE CIRCUIT
A7
i3 20 B38 9
28
32
25
B310
VDCCM & H/U
A:
i10
B:
i11
B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VDC00657
VDC(diag)-27

Step CHECK OTHER LIGHTS TURN ON. Turn the ignition switch to ON. (engine OFF) READ DTC. Read the DTC. <Ref. to VDC(diag)-21, Read Diagnostic Trouble Code (DTC).> CHECK GROUND SHORT CIRCUIT OF HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector (B310) from the VDCCM&H/U. 3) Disconnect the connector (i10) or (i11) from the combination meter. 4) Measure the resistance between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 32 Chassis ground: CHECK VDCCM. 1) Connect the connector (B310) to VDCCM&H/U. 2) Turn the ignition switch to ON. 3) Measure the resistance between the combination meter connector and chassis ground soon after the ignition switch is turned to ON (within 2 seconds). Connector & terminal Normal meter model (i10) No. 5 Chassis ground: Meter with MID model (i11) No. 5 Chassis ground: Check Do other warning lights illuminate? Is DTC displayed? Yes Go to step 2. No Check the combination meter. Go to step 3.
1 2
Perform the diagnosis according to DTC. Go to step 4. Repair the harness connector between VDCCM&H/U and combination meter.
Replace the VDCCM only.
VDC(diag)-28

D: ABS WARNING LIGHT DOES NOT GO OFF

DETECTING CONDITION: Defective combination meter Open circuit of harness TROUBLE SYMPTOM: When starting the engine, the ABS warning light is kept ON. WIRING DIAGRAM:
BATTERY MAIN SBF
SBF-6
E
No.33
BRAKE WARNING LIGHT
: NORMAL METER : A5 METER WITH MID : B5
REVERSE CIRCUIT
REVERSE CIRCUIT
A7
i3 20 B38 9
28
32
25
B310
VDCCM & H/U
A:
i10
B:
i11
B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VDC00657
VDC(diag)-29

Step READ DTC. Read the DTC. <Ref. to VDC(diag)-21, Read Diagnostic Trouble Code (DTC).> CHECK WIRING HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector (B310) from the VDCCM&H/U. 3) Disconnect the connector (i10) or (i11) from the combination meter. 4) Measure the resistance between VDCCM&H/U connector and combination meter connector. Connector & terminal Normal meter model (B310) No. 32 (i10) No. 5: Meter with MID model (B310) No. 32 (i11) No. 5: CHECK POOR CONTACT IN CONNECTOR. Check for poor contact in all connectors. CHECK VDCCM. 1) Connect the connector (B310) to VDCCM&H/U. 2) Turn the ignition switch to ON. 3) Measure the resistance between combination meter connector and chassis ground. Connector & terminal Normal meter model (i10) No. 5 Chassis ground: Meter with MID model (i11) No. 5 Chassis ground: Check Is DTC displayed? Yes No Perform the diag- Go to step 2. nosis according to DTC. Is the resistance less than 0.5 :? Go to step 3. Repair the harness connector between VDCCM&H/U and combination meter.
3 4
Is there poor contact?
Repair the connec- Go to step 4. tor. Is the resistance less than 0.5 :? Check the combi- Replace the nation meter. VDCCM only.
E: VDC INDICATOR LIGHT DOES NOT GO OFF

DETECTING CONDITION: Defective combination meter Defective CAN communication TROUBLE SYMPTOM: When starting the engine, VDC indicator light is kept ON.
Step 1 READ DTC. Read the DTC. <Ref. to VDC(diag)-21, Read Diagnostic Trouble Code (DTC).> CHECK LAN SYSTEM. Is there any fault in LAN sysPerform the diagnosis for LAN system. <Ref. to tem? LAN(diag)-27, OPERATION, Read Diagnostic Trouble Code (DTC).> CHECK COMBINATION METER. Is combination meter OK? Check the combination meter. Check Is DTC displayed? Yes Perform the diagnosis according to DTC. Perform the diagnosis according to DTC for LAN system. Replace the VDCCM only. No Go to step 2.
Go to step 3.
Repair the combination meter.
VDC(diag)-30

F: VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT DO NOT GO OFF
DETECTING CONDITION: Defective combination meter Defective CAN communication Defective engine VDC OFF switch is shorted. TROUBLE SYMPTOM: When starting the engine, VDC OFF indicator light is kept ON. NOTE: When pressing the VDC OFF switch for 10 seconds or more, the VDC OFF indicator light goes off and cannot operate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status is restored.
1 Yes No Perform the diag- Go to step 2. nosis according to DTC. Does the malfunction indicator Repair the engine. Go to step 3. light illuminate? CHECK ENGINE COOLANT TEMPERAWhen the engine coolant tem- Normal operation Go to step 4. TURE. perature is too low, VDC warnWarm up the engine and check if VDC warning ing light and VDC OFF indicator light and VDC OFF indicator light illumination light illuminate. Do the lights go condition changes. off when the engine is warmed up? CHECK VDC OFF SWITCH. Is the VDC OFF switch normal? Go to step 5. Replace the VDC Remove and check VDC OFF switch. <Ref. to OFF switch. VDC-24, VDC OFF Switch.> CHECK LAN SYSTEM. Is there any fault in LAN sysPerform the diag- Go to step 6. Perform the diagnosis for LAN system. <Ref. to tem? nosis according to LAN(diag)-27, OPERATION, Read Diagnostic DTC for LAN sysTrouble Code (DTC).> tem. CHECK COMBINATION METER. Is combination meter OK? Replace the Repair the combiCheck the combination meter. VDCCM only. nation meter. Step READ DTC. Read the DTC. <Ref. to VDC(diag)-21, Read Diagnostic Trouble Code (DTC).> CHECK ENGINE. Check Is DTC displayed?
2 3
VDC(diag)-31

G: BRAKE WARNING LIGHT DOES NOT GO OFF

DETECTING CONDITION: Brake warning light circuit is shorted. Defective sensor/connector TROUBLE SYMPTOM: After starting the engine, the brake warning light remains lit though the parking lever is released. WIRING DIAGRAM:
BATTERY MAIN SBF
SBF-6
E
A3
PARKING BRAKE FLUID LEVEL WARNING LIGHT

REVERSE CIRCUIT
*1
: NORMAL METER : A8 METER WITH MID : A4 : NORMAL METER : B10 METER WITH MID : A8
*2
A7
*2
i3 B38 20 15 16
*1
i1 B36
B16 1 2 BRAKE FLUID LEVEL SWITCH 8 B310 VDCCM & H/U B404
E
PARKING SWITCH
B16
i1
B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
A:
i10
1 2
3 4 1 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 B38
6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22
B:
i11
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VDC00658
VDC(diag)-32

Step CHECK INSTALLATION OF VDCCM&H/U CONNECTOR. 1) Turn the ignition switch to OFF. 2) Check that the VDCCM&H/U connector is inserted until it is locked by clamp. READ DTC. Read the DTC. <Ref. to VDC(diag)-21, Read Diagnostic Trouble Code (DTC).> CHECK BRAKE FLUID AMOUNT. Check the amount of brake fluid in the reservoir tank of master cylinder. CHECK BRAKE FLUID LEVEL SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the level switch connector (B16) from master cylinder. 3) Measure the resistance of master cylinder terminals. Terminals No. 1 No. 2: CHECK PARKING BRAKE SWITCH. 1) Disconnect the connector (B404) from parking brake switch. 2) Release the parking brake. 3) Measure the resistance between parking brake switch terminal and chassis ground. CHECK GROUND SHORT OF HARNESS. 1) Disconnect the connectors (i10 and i11) from the combination meter. 2) Measure the resistance between combination meter connector and chassis ground. Connector & terminal Normal meter model (i10) No. 8 Chassis ground: (i11) No. 10 Chassis ground: Meter with MID model (i10) No. 8 Chassis ground: (i10) No. 4 Chassis ground: CHECK HARNESS CONNECTOR. 1) Disconnect the connector (B310) from the VDCCM&H/U. 2) Disconnect the connector (i10) from combination meter. 3) Measure the resistance between VDCCM&H/U connector and combination meter connector. Connector & terminal (B310) No. 8 (i10) No. 7: CHECK POOR CONTACT IN CONNECTOR. Check for poor contact in all connectors. CHECK VDCCM. 1) Connect the connector (B310) to VDCCM&H/U. 2) Turn the ignition to ON. 3) Measure the resistance between combination meter connector and chassis ground. Connector & terminal (i10) No. 7 Chassis ground: Check Is the connector firmly inserted? Yes Go to step 2. No Insert the VDCCM&H/U connector until it is locked by clamp.
Is DTC displayed?
Perform the diag- Go to step 3. nosis according to DTC. Is the amount of brake fluid Go to step 4. Replenish brake between the lines of MAX and fluid to the speciMIN? fied value. Is the resistance 1 M: or Go to step 5. Replace the masmore? ter cylinder.
Go to step 6.
Replace the parking brake switch.
Go to step 7.
Repair the harness connector between combination meter and brake fluid level switch or parking brake switch.
Repair the harness connector between VDCCM&H/U and combination meter.
8 9
Repair the connec- Go to step 9. tor. Is the resistance less than 0.5 :? Check the combi- Replace the nation meter. VDCCM only. Is there poor contact?
VDC(diag)-33


A: LIST
DTC Detailed code 07B0H 072FH 0736H 0737H 0738H 073AH 073CH 06B0H 062FH 0636H 0637H 0638H 063AH 063CH 09B0H 092FH 0936H 0937H 0938H 093AH 093CH 08B0H 082FH 0836H 0837H 0838H 083AH 083CH 0A11H 0A21H 0A42H 0A46H 0A50H 0DB8H 0DC0H 0EB8H 0EC0H Display Front Right ABS Sensor Circuit Open or Shorted Battery Content of diagnosis Open/high input of front ABS wheel speed sensor RH Reference target <Ref. to VDC(diag)-39, DTC C0021 FRONT RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-42, DTC C0022 FRONT RIGHT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-39, DTC C0023 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-42, DTC C0024 FRONT LEFT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-39, DTC C0025 REAR RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-42, DTC C0026 REAR RIGHT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-40, DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-43, DTC C0028 REAR LEFT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0021
C0022
Front Right ABS Sensor Signal
Front ABS wheel speed sensor RH signal malfunction
C0023
Front Left ABS Sensor Circuit Open or Shorted Battery
Open/high input of front ABS wheel speed sensor LH
C0024
Front Left ABS Sensor Signal
Front ABS wheel speed sensor LH signal malfunction
C0025
Rear Right ABS Sensor Circuit Open or Shorted Battery
Open/high input of rear ABS wheel speed sensor RH
C0026
Rear Right ABS Sensor Signal
Rear ABS wheel speed sensor RH signal malfunction
C0027
Rear Left ABS Sensor Circuit Open or Shorted Battery
Open/high input of rear ABS wheel speed sensor LH
C0028
Rear Left ABS Sensor Signal
Rear ABS wheel speed sensor LH signal malfunction
C0029
Any One of Four ABS Sensors Signal
ABS wheel speed sensor signal malfunction in one of four wheels Front inlet solenoid valve RH malfunction in VDCCM&H/U Front outlet solenoid valve RH malfunction in VDCCM&H/U
<Ref. to VDC(diag)-46, DTC C0029 ANY OF WHEEL SENSORS SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-48, DTC C0031 FR HOLD VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-48, DTC C0032 FR PRESSURE REDUCING VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0031
FR Hold Valve malfunction FR Pressure Reducing Valve malfunction
C0032
VDC(diag)-34

DTC C0033 Detailed code 0BB8H 0BC0H 0CB8H 0CC0H 11B8H 11C0H 12B8H 12C0H 0FB8H 0FC0H 10B8H 10C0H 0FB5H 11B5H 1AB5H C0041 1620H 1630H 16C0H 0316H 031CH 0322H 0324H 2921H Display FL Hold Valve malfunction FL Pressure Reducing Valve malfunction RR Hold Valve malfunction RR Pressure Reducing Valve malfunction RL Hold Valve malfunction RL Pressure Reducing Valve malfunction Any One of Four Solenoid Valves Electrical Control Module Parameter selection error Power Supply Voltage Failure TCM Communication Circuit Incorrect VDC Control Module specifications Content of diagnosis Front inlet solenoid valve LH malfunction in VDCCM&H/U Front outlet solenoid valve LH malfunction in VDCCM&H/U Rear inlet solenoid valve RH malfunction in VDCCM&H/U Rear outlet solenoid valve RH malfunction in VDCCM&H/U Rear inlet solenoid valve LH malfunction in VDCCM&H/U Rear outlet solenoid valve LH malfunction in VDCCM&H/U Reference target <Ref. to VDC(diag)-48, DTC C0033 FL HOLD VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-48, DTC C0034 FL PRESSURE REDUCING VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-48, DTC C0035 RR HOLD VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-48, DTC C0036 RR PRESSURE REDUCING VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-49, DTC C0037 RL HOLD VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-49, DTC C0038 RL PRESSURE REDUCING VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0034
C0035
C0036
C0037
C0038
C0039
Solenoid valve malfunc- <Ref. to VDC(diag)-49, DTC C0039 ANY ONE OF tion in one of four FOUR SOLENOID VALVES, Diagnostic Procewheels dure with Diagnostic Trouble Code (DTC).> VDC control module malfunction <Ref. to VDC(diag)-52, DTC C0041 ECM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC control module <Ref. to VDC(diag)-54, DTC C0041 PARAMETER parameter selection fail- SELECTION ERROR, Diagnostic Procedure with ure Diagnostic Trouble Code (DTC).> Power voltage malfunction CAN communication failure of transmission control module Different VDC control module specification AT control module malfunction <Ref. to VDC(diag)-55, DTC C0042 POWER SUPPLY VOLTAGE FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-57, DTC C0044 TCM COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-58, DTC C0045 INCORRECT VDC CONTROL MODULE SPECIFICATIONS, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-60, DTC C0045 TCM MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0042
C0044
2922H 2932H C0045 2923H
TCM malfunction
VDC(diag)-35

DTC Detailed code 150EH 1512H 1513H 1514H 1518H 1519H 151AH 151BH 151DH 151EH 151FH 1520H 1531H 1540H 15C0H 021FH 0220H 0221H 0280H 0281H 02B0H 02B1H 02C0H 0580H Display Content of diagnosis Reference target
C0047
<Ref. to VDC(diag)-61, DTC C0047 CAN COMMUNICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0051
Valve Relay
Valve Relay
<Ref. to VDC(diag)-63, DTC C0051 VALVE RELAY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Motor and Motor Relay OFF Failure Motor and Motor Relay ON Failure Motor malfunction
Motor/motor relay OFF malfunction Motor/motor relay ON malfunction Motor
<Ref. to VDC(diag)-65, DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-67, DTC C0052 MOTOR AND MOTOR RELAY ON FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-68, DTC C0052 MOTOR MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-69, DTC C0054 BLS CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-71, DTC C0054 BLS ON MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-73, DTC C0054 BLS OFF MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-75, DTC C0057 ECM COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-76, DTC C0057 ECM CONTROL SYSTEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-49, DTC C0061 NORMAL OPENING VALVE 1 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-49, DTC C0062 NORMAL OPENING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-49, DTC C0063 NORMAL CLOSING VALVE 1 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
C0052
05A0H
0560H
04B0H
BLS Circuit Open
BLS Circuit Open
C0054
043CH
BLS ON malfunction
BLS ON malfunction
04C1H
BLS OFF Malfunction ECM Communication Circuit ECM Control System Normal Opening Valve 1 malfunction Normal Opening Valve 2 malfunction Normal Closing Valve 1 malfunction
BLS OFF Malfunction CAN communication failure of engine control module Coordinate control prohibition of engine control module Secondary cut valve malfunction in VDCCM&H/U Primary cut valve malfunction in VDCCM&H/ U Secondary suction valve malfunction in VDCCM&H/U
2931H C0057 2933H 19B8H 19C0H 1AB8H 1AC0H 1BB8H 1BC0H
C0061
C0062
C0063
VDC(diag)-36

DTC C0064 Detailed code 1CB8H 1CC0H Display Normal Closing Valve 2 malfunction Steering Angle Sensor Offset is too big Change range of Steering Angle Sensor is too big Content of diagnosis Primary suction valve malfunction in VDCCM&H/U Reference target <Ref. to VDC(diag)-50, DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
2130H
2134H 212EH 2132H 2136H 2138H 213CH 2150H 2151H 2152H 2153H 2154H 2155H 2156H 2157H 2158H 2159H 215AH 2104H 1E03H 1E1AH 1E1EH 1E22H 1E26H 1E28H 1E2CH 1E34H 1E38H 1E3AH 1E3CH 1E3FH 1EACH C0072 1E04H 1E05H 1E07H
<Ref. to VDC(diag)-77, DTC C0071 STEERING Excessive steering ANGLE SENSOR OFFSET IS TOO BIG, Diagangle sensor output offnostic Procedure with Diagnostic Trouble Code set (DTC).> <Ref. to VDC(diag)-79, DTC C0071 CHANGE Excessive variation RANGE OF STEERING ANGLE SENSOR IS amount of steering TOO BIG, Diagnostic Procedure with Diagnostic angle sensor output Trouble Code (DTC).>
C0071
Steering Angle Sensor Op
Steering angle sensor output
<Ref. to VDC(diag)-81, DTC C0071 STEER ANGLE SENSOR OP, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Steering angle sensor malfunction
Steering angle sensor power supply malfunction
<Ref. to VDC(diag)-83, DTC C0071 STEERING ANGLE SENSOR MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Yaw Rate Sensor Output
Yaw rate sensor output
<Ref. to VDC(diag)-85, DTC C0072 ABNORMAL YAW RATE SENSOR OUTPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Voltage inputted to Yaw Rate Sensor exceeds specification Abnormal Yaw Rate Sensor reference voltage Change range of Yaw Rate Sensor Signal is too big Yaw Rate Sensor Communication
1EAAH
1E30H 1E06H 1EABH 1EAEH
<Ref. to VDC(diag)-87, DTC C0072 VOLTAGE INPUTTED TO YAW RATE SENSOR EXCEEDS SPECIFICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-89, DTC C0072 ABNORMAL Yaw rate sensor referYAW RATE SENSOR REFERENCE VOLTAGE, ence Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-91, DTC C0072 CHANGE Excessive variation RANGE OF YAW RATE SENSOR SIGNAL IS amount of yaw rate senTOO BIG, Diagnostic Procedure with Diagnostic sor output Trouble Code (DTC).> Yaw rate sensor power supply/output Yaw rate sensor communication <Ref. to VDC(diag)-94, DTC C0072 YAW RATE SENSOR COMMUNICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-37

DTC Detailed code 1D46H 1D47H 1D44H 1D45H 1DA0H 1DA2H 1D49H Display Lateral G Sensor offset is too big Content of diagnosis Excessive amount of lateral G sensor output offset Reference target <Ref. to VDC(diag)-96, DTC C0073 LATERAL G SENSOR OFFSET IS TOO BIG, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-96, DTC C0073 ABNORMAL LATERAL G SENSOR OUTPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-97, DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-93, DTC C0073 LATERAL G SENSOR COMMUNICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-99, DTC C0074 PRESSURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to VDC(diag)-100, DTC C0081 SYSTEM FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Lateral G Sensor output Lateral G sensor output
C0073
Excessive Lateral G Sensor signal Lateral G Sensor Communication
Excessive lateral G sensor output Lateral G sensor communication
1DA4H 1F4EH 1F90H 1FA1H 1FB0H 1FB1H 1FC0H 2201H 2202H
C0074
Pressure Sensor
Pressure sensor
C0081
System Failure
System Failure
VDC(diag)-38


A: DTC C0021 FRONT RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT
NOTE: For the diagnostic procedure, refer to DTC C0027 RL WHEEL SPEED SENSOR CIRCUIT OPEN/HIGH INPUT. <Ref. to VDC(diag)-40, DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B: DTC C0023 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORT

C: DTC C0025 REAR RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT

VDC(diag)-39

D: DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT

DTC DETECTING CONDITION: Defective ABS wheel speed sensor (broken wire, input voltage too high) Defective harness connector TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. WIRING DIAGRAM:
B310
VDCCM & H/U
26 1
2 27
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
5 14
6 15
B98 R2
TWISTED PAIR LINE
B15 2 1 2 1
B6 1 2
R73 1 2
TWISTED PAIR LINE
R72
E
FRONT ABS WHEEL SPEED SENSOR LH B6 B15 R72 R73 FRONT ABS WHEEL SPEED SENSOR RH B98 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 22 23 24 25 REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
2 1
1 2
25
5 6
3 4
VDC00501
VDC(diag)-40

Step CHECK POOR CONTACT IN CONNECTOR. Check if there is poor contact between VDCCM&H/U and ABS wheel speed sensor. CHECK HARNESS CONNECTOR BETWEEN VDCCM&H/U AND ABS WHEEL SPEED SENSOR. 1) Disconnect the connector (B310) from the VDCCM&H/U. 2) Disconnect the connector from the ABS wheel speed sensor. 3) Measure the resistance between VDCCM&H/U connector and ABS wheel speed sensor connector. Connector & terminal DTC C0021 (B310) No. 6 (B6) No. 1: (B310) No. 5 (B6) No. 2: DTC C0023 (B310) No. 1 (B15) No. 1: (B310) No. 26 (B15) No. 2: DTC C0025 (B310) No. 3 (R72) No. 1: (B310) No. 4 (R72) No. 2: DTC C0027 (B310) No. 2 (R73) No. 1: (B310) No. 27 (R73) No. 2: CHECK GROUND SHORT OF HARNESS. Measure the resistance between VDCCM&H/U connector and chassis ground. Connector & terminal DTC C0021 (B310) No. 6 Chassis ground: DTC C0023 (B310) No. 1 Chassis ground: DTC C0025 (B310) No. 4 Chassis ground: DTC C0027 (B310) No. 27 Chassis ground: CHECK ABS WHEEL SPEED SENSOR POWER SUPPLY CIRCUIT. 1) Connect the VDCCM&H/U connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between ABS wheel speed sensor connector and chassis ground. Connector & terminal DTC C0021 (B6) No. 2 (+) Chassis ground (): DTC C0023 (B15) No. 2 (+) Chassis ground (): DTC C0025 (R72) No. 1 (+) Chassis ground (): DTC C0027 (R73) No. 1 (+) Chassis ground (): Check Is there poor contact? Yes No Repair the connec- Go to step 2. tor. Repair the harness connector between VDCCM&H/U and ABS wheel speed sensor.
Go to step 4.
Repair the harness connector between VDCCM&H/U and ABS wheel speed sensor.
Go to step 6.
Go to step 5.
VDC(diag)-41

Step CHECK VDCCM&H/U POWER SUPPLY CIRCUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the VDCCM&H/U connector. 3) Turn the ignition switch to ON. 4) Measure the voltage between VDCCM&H/U connector terminals. Connector & terminal (B310) No. 28 (+) (B310) No. 25 (): CHECK ABS WHEEL SPEED SENSOR SIGNAL. 1) Install the ABS wheel speed sensor. 2) Prepare an oscilloscope. 3) Check the ABS wheel speed sensor. <Ref. to ABS-14, ABS WHEEL SPEED SENSOR, INSPECTION, Front ABS Wheel Speed Sensor.> CHECK VDCCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, PROCEDURE, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the voltage 10 15 V? Yes Go to step 6. No Check the generator, battery and VDCCM&H/U power supply circuit.
Is the pattern the same waveform as shown in the figure?
Go to step 7.
Replace the ABS wheel speed sensor.
Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
Go to step 8.
E: DTC C0022 FRONT RIGHT ABS SENSOR SIGNAL

NOTE: For the diagnostic procedure, refer to DTC C0028 RL WHEEL SPEED SENSOR SIGNAL. <Ref. to VDC(diag)-43, DTC C0028 REAR LEFT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC C0024 FRONT LEFT ABS SENSOR SIGNAL

G: DTC C0026 REAR RIGHT ABS SENSOR SIGNAL

VDC(diag)-42

H: DTC C0028 REAR LEFT ABS SENSOR SIGNAL

DTC DETECTING CONDITION: Defective ABS wheel speed sensor signal (noise, irregular signal, etc.) Defective harness connector TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. WIRING DIAGRAM:
B310
VDCCM & H/U
26 1
2 27
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
5 14
6 15
B98 R2
TWISTED PAIR LINE
B15 2 1 2 1
B6 1 2
R73 1 2
TWISTED PAIR LINE
R72
E
2 1
1 2
25
5 6
3 4
VDC00501
VDC(diag)-43

Step CHECK OUTPUT OF ABS WHEEL SPEED SENSOR USING SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in the Subaru Select Monitor. 2) Read the defective ABS wheel speed sensor output. CHECK POOR CONTACT IN CONNECTOR. Turn the ignition switch to OFF. CHECK CAUSE OF SIGNAL NOISE. Make sure the radio wave devices and electronic components are installed correctly. Check Yes Does the speed indicated on Go to step 2. the display change in response to the speedometer reading during acceleration/deceleration when the steering wheel is in the straight-ahead position? Is there poor contact in connec- Repair the connectors between VDCCM&H/U and tor. ABS wheel speed sensor? Are the radio wave devices and Go to step 4. electronic components installed correctly? Install the noise sources apart from sensor harness. Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).> Is the ABS wheel speed sensor Go to step 8. installation bolt tightened 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)? Go to step 10. No Go to step 7.
Go to step 3.
CHECK CAUSE OF SIGNAL NOISE. Are noise sources installed? Check if the noise sources (such as an antenna) are installed near the sensor harness. CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, PROCEDURE, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed?
Install the radio wave devices and electronic components properly. Go to step 5.
Go to step 6.
CHECK INSTALLATION OF ABS WHEEL SPEED SENSOR.
CHECK ABS WHEEL SPEED SENSOR SIGNAL. 1) Install the ABS wheel speed sensor. 2) Prepare an oscilloscope. 3) Check the ABS wheel speed sensor. <Ref. to ABS-14, ABS WHEEL SPEED SENSOR, INSPECTION, Front ABS Wheel Speed Sensor.> CHECK ABS WHEEL SPEED SENSOR OR MAGNETIC ENCODER.
Does the oscilloscope indicate the waveform pattern like shown in the figure when the tire is slowly turned? Does the oscilloscope indication repeat the waveform pattern like shown in the figure when the tire is slowly turned in equal speed for one rotation or more? Are there foreign matter, breakage or damage at the tip of ABS wheel speed sensor or magnetic encoder?
Tighten the ABS wheel speed sensor installation bolts. Go to step 9.
10
CHECK CAUSE OF SIGNAL NOISE. Make sure the radio wave devices and electronic components are installed correctly.
Remove dirt thor- Go to step 10. oughly. Also replace the ABS wheel speed sensor or magnetic encoder as a unit with hub unit bearing if it is broken or damaged. Are the radio wave devices and Go to step 11. Install the radio electronic components wave devices and installed correctly? electronic components properly.
VDC(diag)-44

Step Check CHECK CAUSE OF SIGNAL NOISE. Is the noise sources installed? Check if the noise sources (such as an antenna) are installed near the sensor harness. CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, PROCEDURE, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed? Yes Go to step 12. No Install the noise sources apart from sensor harness. Go to step 13.
11
12
13
It results from a temporary noise interference. NOTE: Though the ABS warning light remains on at this time, this is normal. Drive the vehicle at 12 km/h (7 MPH) or more in order to turn ABS warning light off. Be sure to drive the vehicle and check that the warning light goes off.
VDC(diag)-45

I:
DTC C0029 ANY OF WHEEL SENSORS SIGNAL
DTC DETECTING CONDITION: Defective ABS wheel speed sensor signal (noise, irregular signal, etc.) Defective magnetic encoder When a wheel is turned freely for a long time TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. EBD may not operate. NOTE: Brake warning light illuminates as well as ABS warning light when EBD does not operate. WIRING DIAGRAM:
B310
VDCCM & H/U
26 1
2 27
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
5 14
6 15
B98 R2
TWISTED PAIR LINE
B15 2 1 2 1
B6 1 2
R73 1 2
TWISTED PAIR LINE
R72
E
2 1
1 2
25
5 6
3 4
VDC00501
VDC(diag)-46

Step Check WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely? NOT. Check if the wheels have been turned freely for one minute or more, such as when the vehicle is jacked-up, under full-lock cornering or when the wheels are not in contact with road surface. Yes No VDC is normal. Go to step 2. Clear the memory. NOTE: This diagnostic trouble code may sometimes occur if the wheels turn freely for a long time, for example when the vehicle is towed or jackedup, or when steering wheel is continuously turned all the way. Go to step 3. Replace the tire. Replace the tire. Go to step 5. Go to step 6. Go to step 4. Adjust the tire pressure. Tighten the ABS wheel speed sensor installation bolts. Go to step 7.
2 3 4 5
CHECK TIRE SPECIFICATIONS. Turn the ignition switch to OFF. CHECK WEAR OF TIRE. CHECK TIRE INFLATION PRESSURE. CHECK INSTALLATION OF ABS WHEEL SPEED SENSOR.
Are the tire specifications correct? Is the tire worn excessively? Is the tire pressure correct?
Are the ABS wheel speed sensor installation bolts tightened 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)? (For four wheels) CHECK ABS WHEEL SPEED SENSOR SIG- Does the oscilloscope indicate NAL. the waveform pattern like 1) Install the ABS wheel speed sensor. shown in the figure when the 2) Prepare an oscilloscope. tire is slowly turned? Does the 3) Check the ABS wheel speed sensor. <Ref. oscilloscope indication repeat to ABS-14, ABS WHEEL SPEED SENSOR, the waveform pattern like INSPECTION, Front ABS Wheel Speed Sen- shown in the figure when the sor.> tire is slowly turned in equal speed for one rotation or more? CHECK ABS WHEEL SPEED SENSOR OR Are there foreign matter, breakMAGNETIC ENCODER. age or damage at the tip of ABS wheel speed sensor or magnetic encoder?
Go to step 8.
CHECK VDCCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, PROCEDURE, Inspection Mode.> 4) Read the DTC.
Remove dirt thor- Go to step 8. oughly. Also replace the ABS wheel speed sensor or magnetic encoder as a unit with hub unit bearing if it is broken or damaged. Replace the Go to step 9. VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).>
VDC(diag)-47

Step CHECK OTHER DTC DETECTION. Check Is any other DTC displayed? Yes Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).> No It results from a temporary noise interference. NOTE: Though the ABS warning light remains on at this time, this is normal. Drive the vehicle at 12 km/h (7 MPH) or more in order to turn ABS warning light off. Be sure to drive the vehicle and check that the warning light goes off.
J: DTC C0031 FR HOLD VALVE MALFUNCTION

NOTE: For the diagnostic procedure, refer to DTC C0064 VDC SWITCHING VALVE 2 (P). <Ref. to VDC(diag)-50, DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
K: DTC C0032 FR PRESSURE REDUCING VALVE MALFUNCTION

NOTE: For the diagnostic procedure, refer to DTC C0064 VDC SWITCHING VALVE 2 (P). <Ref. to VDC(diag)-50, DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
L: DTC C0033 FL HOLD VALVE MALFUNCTION

NOTE: For the diagnostic procedure, refer to C0064 VDC SWITCHING VALVE 2 (P). <Ref. to VDC(diag)-50, DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
M: DTC C0034 FL PRESSURE REDUCING VALVE MALFUNCTION

N: DTC C0035 RR HOLD VALVE MALFUNCTION

O: DTC C0036 RR PRESSURE REDUCING VALVE MALFUNCTION

VDC(diag)-48

P: DTC C0037 RL HOLD VALVE MALFUNCTION

Q: DTC C0038 RL PRESSURE REDUCING VALVE MALFUNCTION

R: DTC C0039 ANY ONE OF FOUR SOLENOID VALVES

S: DTC C0061 NORMAL OPENING VALVE 1 MALFUNCTION

T: DTC C0062 NORMAL OPENING VALVE 2 MALFUNCTION

U: DTC C0063 NORMAL CLOSING VALVE 1 MALFUNCTION

VDC(diag)-49

V: DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION

DTC DETECTING CONDITION: Defective harness connector Defective VDCH/U solenoid valve TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. VDC does not operate. WIRING DIAGRAM:
BATTERY
MAIN SBF
GENERATOR SBF-6
IGNITION SWITCH
No.33
E
28 25 B310 VDCCM & H/U B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00463
VDC(diag)-50

Step Check CHECK VDCCM&H/U INPUT VOLTAGE. Is the voltage 10 15 V? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the VDCCM&H/U. 3) Run the engine at idle. 4) Measure the voltage between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 28 (+) Chassis ground (): CHECK VDCCM&H/U GROUND CIRCUIT. Is the resistance less than 0.5 :? 1) Turn the ignition switch to OFF. 2) Measure the resistance between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 25 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector between generator, battery and VDCCM&H/U? CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed? Yes Go to step 2. No Repair the power supply circuit.
Go to step 3.
Repair the VDCCM&H/U ground harness.
Repair the connec- Go to step 4. tor. Replace the Go to step 5. VDCCM&H/U. <Ref. to VDC-7, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-51

W: DTC C0041 ECM

DTC DETECTING CONDITION: Defective VDCCM&H/U TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. VDC does not operate. WIRING DIAGRAM:
B310 VDCCM & H/U
B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
25
VDC00464
VDC(diag)-52

Step Check CHECK VDCCM&H/U GROUND CIRCUIT. Is the resistance less than 0.5 :? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the VDCCM&H/U. 3) Measure the resistance between VDCCM&H/U and chassis ground. Connector & terminal (B310) No. 25 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Is there poor contact of the connector between the battery, ignition switch and VDCCM&H/U? CHECK CAUSE OF SIGNAL NOISE. Are the radio wave devices and electronic components installed correctly? CHECK CAUSE OF SIGNAL NOISE. Yes Go to step 2. No Repair the VDCCM&H/U ground harness.
Repair the connec- Go to step 3. tor. Go to step 4. Install the radio wave devices and electronic components properly. Go to step 5.
CHECK VDCCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION.
Is there a noise source (such as Install the noise an antenna) installed near the source apart from sensor harness? the sensor harness. Is the same DTC displayed? Replace the Go to step 6. VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Is any other DTC displayed? Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-53

X: DTC C0041 PARAMETER SELECTION ERROR

DTC DETECTING CONDITION: VDCCM parameter selection failure TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. VDC does not operate. NOTE: When the VDCCM or VDCCM&H/U is replaced, this DTC may be memorized.
1 2 Step CHECK VDCCM&H/U REPLACEMENT HISTORY. CHECK VDCCM IDENTIFICATION NUMBER. Check the identification number on the sticker attached on the VDCCM side. AT: T3 (2.5 L turbo models and OUTBACK 3.0 L models) T7 (Sedan 3.0L with 18 inch tire model) TA (2.5L non-turbo model and sedan 3.0L with 17 inch tire model) MT: T4 (2.5L turbo model) TB (2.5L non-turbo model) CHECK VDCCM&H/U IDENTIFICATION NUMBER. Check the identification number stamped on the upper side of the H/U. AT: T3 (2.5 L turbo models and OUTBACK 3.0 L models) T7 (Sedan 3.0L with 18 inch tire model) TA (2.5L non-turbo model and sedan 3.0L with 17 inch tire model) MT: T4 (2.5L turbo model) TB (2.5L non-turbo model) CHECK PARAMETER SELECTED FOR VDCCM. <Ref. to VDC(diag)-17, PARAMETER CHECK, OPERATION, Subaru Select Monitor.> Check Yes Is there replacement history of Go to step 2. VDCCM alone? Is the identification number cor- Go to step 4. rect? No Go to step 3. Replace the VDCCM only.
Is the identification number cor- Go to step 4. rect?
Replace the VDCCM&H/U.
Does the parameter registered Replace the to the VDCCM match with the VDCCM only. target vehicle?
Select and register the correct parameter. <Ref. to VDC(diag)-16, PARAMETER SELECTION, OPERATION, Subaru Select Monitor.>
VDC(diag)-54

Y: DTC C0042 POWER SUPPLY VOLTAGE FAILURE

DTC DETECTING CONDITION: Improper VDCCM&H/U power supply voltage TROUBLE SYMPTOM: ABS does not operate. EBD may not operate. VDC does not operate. NOTE: Warning lights go off if voltage returns. WIRING DIAGRAM:
BATTERY
MAIN SBF
GENERATOR SBF-6
IGNITION SWITCH
No.33
E
28 25 B310 VDCCM & H/U B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00463
VDC(diag)-55

Step Check CHECK GENERATOR. Is the voltage 10 15 V? 1) Start the engine. 2) Run the engine at idle after warming up. 3) Measure the voltage between generator terminal B and chassis ground. Terminals Generator B terminal (+) Chassis ground (): CHECK BATTERY TERMINAL. Are the positive and negative Turn the ignition switch to OFF. battery terminals clamped tightly? CHECK VDCCM&H/U INPUT VOLTAGE. Is the voltage 10 15 V? 1) Disconnect the connector from the VDCCM&H/U. 2) Run the engine at idle. 3) Operate devices such as headlights, air conditioner, defogger, etc. which produce an electrical load. 4) Measure the voltage between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 28 (+) Chassis ground (): CHECK VDCCM&H/U GROUND CIRCUIT. Is the resistance less than 0.5 :? 1) Turn the ignition switch to OFF. 2) Measure the resistance between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 25 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector between generator, battery and VDCCM&H/U? CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed? Yes Go to step 2. No Repair the generator.
Go to step 3.
Tighten the terminal. Repair the power supply circuit.
Go to step 4.
Go to step 5.
Repair the connec- Go to step 6. tor. Replace the Go to step 7. VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-56

Z: DTC C0044 TCM COMMUNICATION CIRCUIT

DTC DETECTING CONDITION: No CAN signal from TCM. TROUBLE SYMPTOM: ABS does not operate. VDC does not operate.
1 Step Check CHECK LAN SYSTEM. Is there any fault in LAN sysPerform the diagnosis for LAN system. <Ref. to tem? LAN(diag)-27, OPERATION, Read Diagnostic Trouble Code (DTC).> CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM connector? CHECK TCM. Is the TCM normal? Yes No Perform the diag- Go to step 2. nosis according to DTC for LAN system. Repair the connec- Go to step 3. tor. Go to step 4. Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).> <Ref. to 5AT-60, Transmission Control Module (TCM).> Replace the Go to step 5. VDCCM only.
2 3
Perform the diag- It results from a nosis according to temporary noise DTC. <Ref. to interference. VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-57

AA:DTC C0045 INCORRECT VDC CONTROL MODULE SPECIFICATIONS

DTC DETECTING CONDITION: Different control module specification TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. NOTE: When parameter selection for VDCCM is improper, this DTC may be memorized.
1 2 Step Check CHECK VDCCM REPLACEMENT HISTORY. Is there replacement history of VDCCM alone? CHECK VDCCM IDENTIFICATION NUMBER. Is the identification number corCheck the identification number on the sticker rect? attached on the VDCCM side. AT: T3 (2.5 L turbo models and OUTBACK 3.0 L models) T7 (Sedan 3.0L with 18 inch tire model) TA (2.5L non-turbo model and sedan 3.0L with 17 inch tire model) MT: T4 (2.5L turbo model) TB (2.5L non-turbo model) CHECK VDCCM&H/U IDENTIFICATION Is the identification number corNUMBER. rect? Check the identification number stamped on the upper side of the H/U. AT: T3 (2.5 L turbo models and OUTBACK 3.0 L models) T7 (Sedan 3.0L with 18 inch tire model) TA (2.5L non-turbo model and sedan 3.0L with 17 inch tire model) MT: T4 (2.5L turbo model) TB (2.5L non-turbo model) CHECK PARAMETER SELECTED FOR VDC- Does the parameter registered CM. to the VDCCM match with the <Ref. to VDC(diag)-17, PARAMETER CHECK, target vehicle? OPERATION, Subaru Select Monitor.> Yes Go to step 2. Go to step 4. No Go to step 3. Replace the VDCCM only.
Go to step 4.
CHECK TCM SPECIFICATION. Check the TCM specification.
CHECK AT SYSTEM. 1) Start the engine. 2) Check the DTC in AT system.
Select and register the correct parameter. <Ref. to VDC(diag)-16, PARAMETER SELECTION, OPERATION, Subaru Select Monitor.> Is the specification of TCM Go to step 6. Replace the TCM. same as vehicle specification? <Ref. to 4AT-61, Transmission Control Module (TCM).> <Ref. to 5AT-60, Transmission Control Module (TCM).> Is DTC of AT system displayed? Repair the AT sys- Go to step 7. tem.
Go to step 5.
VDC(diag)-58

Step CHECK ECM SPECIFICATION. Check the ECM specification. Check Yes Is the specification of ECM Go to step 8. same as vehicle specification? No Replace the ECM. <Ref. to FU(H4SO)-39, Engine Control Module (ECM).> <Ref. to FU(H4DOTC)-52, Engine Control Module (ECM).> <Ref. to FU(H6DO)-38, Engine Control Module (ECM).> Go to step 9.
Replace the VDCCM only.
VDC(diag)-59

AB:DTC C0045 TCM MALFUNCTION

DTC DETECTING CONDITION: Defective TCM TROUBLE SYMPTOM: ABS does not operate. VDC does not operate.
1 Step CHECK AT SYSTEM. 1) Start the engine. 2) Check the DTC in AT system. CHECK VDCCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Check Yes No Is DTC of AT system displayed? Repair the AT sys- Go to step 2. tem. Is the same DTC displayed? Replace the VDCCM only. Go to step 3.
VDC(diag)-60

AC:DTC C0047 CAN COMMUNICATION

DTC DETECTING CONDITION: CAN communication line circuit is open or shorted. TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. WIRING DIAGRAM:
BATTERY B310 VDCCM & H/U MAIN SBF
*1 *2
CAN JOINT CONNECTOR B365
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
* *4
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
*4 *3
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
B231 STEERING ANGLE SENSOR YAW RATE & LATERAL G SENSOR B230
*1
E
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3,11,12 AND 13
*2 * *
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 8, 9, 10, 18, 19 AND 20 3 : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6 4 : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 3, 4, 7 AND 8
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-61

Step Check CHECK LAN SYSTEM. Is there any fault in LAN sysPerform the diagnosis for LAN system. <Ref. to tem? LAN(diag)-27, OPERATION, Read Diagnostic Trouble Code (DTC).> CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in VDCCM&H/U connector? CHECK OUTPUT OF STEERING ANGLE Does the output signal change? SENSOR. Connect the Subaru Select Monitor and check output of the steering angle sensor. Yes No Perform the diag- Go to step 2. nosis according to DTC for LAN system. Repair the connec- Go to step 3. tor. Go to step 4. Check output of the steering angle sensor. <Ref. to VDC(diag)-81, DTC C0071 STEER ANGLE SENSOR OP, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> CHECK OUTPUT OF YAW RATE & LATERAL Does the output signal change? Go to step 5. Check output of G SENSOR. the yaw rate & latConnect the Subaru Select Monitor and check eral G sensor. output of the yaw rate & lateral G sensor. <Ref. to VDC(diag)-94, DTC C0072 YAW RATE SENSOR COMMUNICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Temporary poor 1) Connect all connectors. VDCCM only. contact occurs. 2) Clear the memory. <Ref. to VDC(diag)-23, <Ref. to VDC-10, Clear Memory Mode.> REPLACEMENT, 3) Perform the Inspection Mode. <Ref. to VDC Control ModVDC(diag)-22, Inspection Mode.> ule and Hydraulic 4) Read the DTC. Control Unit (VDCCM&H/U).>
2 3
VDC(diag)-62

AD:DTC C0051 VALVE RELAY

DTC DETECTING CONDITION: Defective valve relay TROUBLE SYMPTOM: ABS does not operate. EBD does not operate. VDC does not operate. WIRING DIAGRAM:
BATTERY MAIN SBF
No.1
SBF-6
IGNITION SWITCH
24
MOTOR RELAY
28
SECONDARY SUCTION
SOLENOID VALVE
PRIMARY SUCTION
25 SECONDARY CUT PRIMARY CUT PUMP MOTOR RR OUTLET FR INLET FR OUTLET RL OUTLET FL OUTLET RR INLET RL INLET FL INLET
B310
VALVE RELAY
VDCCM & H/U
No.33
B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00466
VDC(diag)-63

Step CHECK VDCCM&H/U INPUT VOLTAGE. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the VDCCM&H/U. 3) Run the engine at idle. 4) Measure the voltage between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 28 (+) Chassis ground (): (B310) No. 24 (+) Chassis ground (): CHECK VDCCM&H/U INPUT VOLTAGE. Calculate the voltage difference measured in step 1. A: (B310) No. 28 (+) Chassis ground (): B: (B310) No. 24 (+) Chassis ground (): CHECK VDCCM&H/U GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 25 Chassis ground: CHECK VDCCM&H/U VALVE RELAY. Measure the resistance between VDCCM&H/U connector terminals. Connector & terminal (B310) No. 24 (B310) No. 25: CHECK POOR CONTACT IN CONNECTORS. Check Is the voltage 10 15 V? Yes Go to step 2. No Repair the power supply circuit.
Is the voltage difference Repair the power between A and B 2 V or more? supply circuit.
Go to step 3.
Go to step 5.
Is there poor contact in connec- Repair the connector between generator, battery tor. and VDCCM&H/U? Is the same DTC displayed? Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Is any other DTC displayed? Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
Go to step 6.
Go to step 7.
VDC(diag)-64

AE:DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE

DTC DETECTING CONDITION: Defective motor and motor relay Defective harness connector TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. EBD may not operate. WIRING DIAGRAM:
SBF-6
IGNITION SWITCH
23
MOTOR RELAY
28
SECONDARY SUCTION
SOLENOID VALVE
PRIMARY SUCTION
25
VALVE RELAY
M E
VDCCM & H/U
PRIMARY CUT
SECONDARY CUT
PUMP MOTOR
RR OUTLET
FR INLET FR OUTLET
RL OUTLET
FL OUTLET
RR INLET
RL INLET
FL INLET
22
B310
No.33
B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00467
VDC(diag)-65

Step Check CHECK VDCCM&H/U INPUT VOLTAGE. Is the voltage 10 15 V? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the VDCCM&H/U. 3) Turn the ignition switch to ON. 4) Measure the voltage between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 23 (+) Chassis ground (): (B310) No. 28 (+) Chassis ground (): CHECK INSTALLATION OF MOTOR Is the motor ground terminal GROUND. installation bolt tightened 33 Nm (3.4 kgf-m, 24.3 ft-lb)? CHECK VDCCM&H/U GROUND CIRCUIT. Is the resistance less than 0.5 :? 1) Turn the ignition switch to OFF. 2) Measure the resistance between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 25 Chassis ground: (B310) No. 22 Chassis ground: CHECK VDCCM&H/U MOTOR RELAY. Is the resistance 1 M: or Measure the resistance between VDCCM&H/U more? connector terminals. Terminals No. 23 No. 22: CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connecTurn the ignition switch to OFF. tor between generator, battery and VDCCM&H/U? CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed? Yes Go to step 2. No Repair the VDCCM&H/U power supply circuit.
Go to step 3.
Go to step 4.
Tighten the motor ground terminal installation bolt. Repair the VDCCM&H/U ground harness.
Go to step 5.
Repair the connec- Go to step 6. tor. Replace the VDCCM&H/U. <Ref. to VDC-7, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).> Go to step 7.
VDC(diag)-66

AF:DTC C0052 MOTOR AND MOTOR RELAY ON FAILURE

DTC DETECTING CONDITION: Defective motor relay Defective harness connector TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. EBD may not operate. WIRING DIAGRAM:
SBF-6
IGNITION SWITCH
23
MOTOR RELAY
28
SECONDARY SUCTION
SOLENOID VALVE
PRIMARY SUCTION
25
VALVE RELAY
M E
VDCCM & H/U
PRIMARY CUT
SECONDARY CUT
PUMP MOTOR
RR OUTLET
FR INLET FR OUTLET
RL OUTLET
FL OUTLET
RR INLET
RL INLET
FL INLET
22
B310
No.33
B310 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00467
VDC(diag)-67

Step CHECK VDCCM&H/U MOTOR RELAY. 1) Disconnect the connector from the VDCCM&H/U. 2) Measure the resistance between VDCCM&H/U connector terminals. Terminals No. 23 No. 22: CHECK VDCCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the resistance 1 M: or more? Yes Go to step 2. No Replace the VDCCM&H/U. <Ref. to VDC-7, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Go to step 3.
AG:DTC C0052 MOTOR MALFUNCTION

DTC DETECTING CONDITION: Defective motor Defective motor relay Defective harness connector TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. EBD may not operate. NOTE: For the diagnostic procedure, refer to DTC C0052 MOTOR/MOTOR RELAY OFF FAILURE. <Ref. to VDC(diag)-65, DTC C0052 MOTOR AND MOTOR RELAY OFF FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-68

AH:DTC C0054 BLS CIRCUIT OPEN

DTC DETECTING CONDITION: Defective stop light switch TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. WIRING DIAGRAM:
MAIN SBF
BATTERY
E
SBF-2 No.8
7.5A
FUSE (RELAY BLOCK) B225 4
B310
VDCCM & H/U
30
B65 1 2 3 4 1 5 2 6
B159 3 8 4 9 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28
B225 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00502
VDC(diag)-69

Step CHECK OUTPUT OF STOP LIGHT SWITCH WITH SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in the Subaru Select Monitor. 2) Release the brake pedal. 3) Read the stop light switch output in Subaru Select Monitor. CHECK OUTPUT OF STOP LIGHT SWITCH WITH SUBARU SELECT MONITOR. 1) Depress the brake pedal. 2) Read the stop light switch output in Subaru Select Monitor. CHECK IF STOP LIGHTS ILLUMINATE. Depress the brake pedal. CHECK FUSE. Check the fuse (B225) in the relay block. CHECK OPEN CIRCUIT OF HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the VDCCM&H/U. 3) Depress the brake pedal. 4) Measure the voltage between VDCCM&H/U connector and chassis ground. Connector & terminal (B310) No. 30 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTORS. Check Yes Is OFF displayed on the display Go to step 2. screen? No Go to step 3.
Is ON displayed on the display Go to step 6. screen?
Go to step 3.
3 4 5
Does the stop light illuminate? Go to step 4. Is the fuse OK? Is the voltage 10 15 V? Go to step 5. Go to step 6.
Repair the stop light circuit. Replace the fuse. Repair the harness between stop light switch and VDCCM&H/U connector.
Is there poor contact in connec- Repair the connector between stop light switch tor. and VDCCM&H/U? Is the same DTC displayed? Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Is any other DTC displayed? Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
Go to step 7.
Go to step 8.
VDC(diag)-70

AI: DTC C0054 BLS ON MALFUNCTION

MAIN SBF
BATTERY
E
SBF-2 No.8
7.5A
B310
VDCCM & H/U
30
B65 1 2 3 4 1 5 2 6
B159 3 8 4 9 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28
B225 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00502
VDC(diag)-71

Step CHECK STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the stop light switch connector. 3) Measure the resistance of stop light switch terminals. INTERVIEWING CUSTOMERS. Make sure that the operation was performed in which accelerator pedal and brake pedal were depressed simultaneously (with depressing brake pedal with left foot). CHECK VDCCM&H/U. 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Check Yes Is the resistance 1 M: or more Go to step 2. when switch is OFF (when pedal is not depressed)? No Replace the stop light switch.
Were the acceleration pedal and brake pedal depressed simultaneously?
System is normal. (DTC may be recorded while brake is applied during driving.) Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
Go to step 3.
Go to step 4.
VDC(diag)-72

AJ:DTC C0054 BLS OFF MALFUNCTION

MAIN SBF
BATTERY
E
SBF-2 No.8
7.5A
B310
VDCCM & H/U
30
B65 1 2 3 4 1 5 2 6
B159 3 8 4 9 1 3 5 7 2 4 6 8 9 10 11 12 25 26 27 28
B225 13 14 15 16 29 30 31 32 17 18 19 20 33 34 35 36 21 22 23 24 37 38 39 40 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
VDC00502
VDC(diag)-73

Step CHECK STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the stop light switch connector. 3) Measure the resistance of stop light switch terminals. CHECK POWER SUPPLY OF STOP LIGHT SWITCH. Measure the voltage between the stop light switch terminal and chassis ground. Connector & terminal (B65) No. 2 (+) Chassis ground (): CHECK STOP LIGHT SWITCH HARNESS. 1) Disconnect the connector from the VDCCM&H/U. 2) Measure the resistance between VDCCM&H/U and stop light switch. Connector & terminal (B65) No. 3 (B310) No. 30: CHECK POOR CONTACT IN CONNECTORS. Check Is the resistance 0.5 : or less when the switch is ON (when pedal is depressed)? Yes Go to step 2. No Replace the stop light switch.
Go to step 3.
Repair the power supply circuit of stop light.
Repair the stop light switch circuit.
Is there poor contact in connec- Repair the connector between stop light switch tor. and VDCCM&H/U? Is the same DTC displayed? Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Is any other DTC displayed? Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
Go to step 5.
Go to step 6.
VDC(diag)-74

AK:DTC C0057 ECM COMMUNICATION CIRCUIT

DTC DETECTING CONDITION: No CAN signal from ECM. TROUBLE SYMPTOM: ABS does not operate. VDC does not operate.
1 Step Check CHECK LAN SYSTEM. Is there any fault in LAN sysPerform the diagnosis for LAN system. <Ref. to tem? LAN(diag)-27, OPERATION, Read Diagnostic Trouble Code (DTC).> CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in ECM connector? CHECK ECM. Is ECM normal? CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed? Yes Perform the diagnosis according to DTC for LAN system. Repair the connector. Go to step 4. Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).> No Go to step 2.
2 3 4
Go to step 3. Replace the ECM. Go to step 5.
VDC(diag)-75

AL:DTC C0057 ECM CONTROL SYSTEM

DTC DETECTING CONDITION: Cooperation control prohibition of ECM TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. NOTE: Warning lights go off if the cooperation control of ECM returns.
1 Step CHECK WARNING LIGHT. Check whether the VDC warning light illuminates after driving for 1 minute or more at a speed of 10 km/h or more. Check Yes Does the VDC warning light illu- Go to step 2. minate? No VDC is normal. Perform the Clear Memory Mode. NOTE: If cranking operation is performed while driving, DTC may be memorized. Repair the connec- Go to step 3. tor. Go to step 4. Replace the ECM. Replace the Go to step 5. VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diag- It results from a nosis according to temporary noise DTC. <Ref. to interference. VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
2 3 4
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in ECM connector? CHECK ECM. Is ECM normal? CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed?
VDC(diag)-76

AM:DTC C0071 STEERING ANGLE SENSOR OFFSET IS TOO BIG

DTC DETECTING CONDITION: Defective steering angle sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM:
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
*3 *4 *4 *3
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-77

Step CHECK STEERING WHEEL. 1) Drive the vehicle on a flat road. 2) Park the vehicle straight. 3) Check the steering wheel for deviation from center. CHECK VDCCM&H/U. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Yes Is the deviation from the center Go to step 2. of steering wheel less than 5? No Perform the centering adjustment of steering wheel.
Replace the Go to step 3. VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-78

AN:DTC C0071 CHANGE RANGE OF STEERING ANGLE SENSOR IS TOO BIG

DTC DETECTING CONDITION: Defective steering angle sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM:
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
*3 *4 *4 *3
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-79

Step CHECK VDCCM&H/U. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the same DTC displayed? Yes No Replace the Go to step 2. VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-80

AO:DTC C0071 STEER ANGLE SENSOR OP

DTC DETECTING CONDITION: Signal does not come from steering angle sensor. TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM:
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
*3 *4 *4 *3
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
Step CHECK POWER SUPPLY FOR STEERING ANGLE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from steering angle sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the steering angle sensor and chassis ground. Connector & terminal (B231) No. 4 (+) Chassis ground ():
Check Is the voltage 10 15 V?
Yes Go to step 2.
No Repair the power supply circuit of steering angle sensor.
VDC(diag)-81

Step CHECK GROUND CIRCUIT OF STEERING ANGLE SENSOR. Measure the resistance between steering angle sensor and chassis ground. Connector & terminal (B231) No. 3 Chassis ground: CHECK STEERING ANGLE SENSOR HARNESS. 1) Disconnect the connector from the VDCCM&H/U. 2) Measure the resistance between VDCCM&H/U and steering angel sensor. Connector & terminal (B231) No. 1 (B310) No. 10: (B231) No. 2 (B310) No. 35: CHECK GROUND SHORT CIRCUIT OF STEERING ANGLE SENSOR HARNESS. Measure the resistance between steering angle sensor and chassis ground. Connector & terminal (B231) No. 1 Chassis ground: (B231) No. 2 Chassis ground: CHECK STEERING ANGLE SENSOR. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK VDCCM&H/U. 1) Turn the ignition switch to OFF. 2) Replace the steering angle sensor. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Yes Is the resistance less than 0.5 :? Go to step 3. No Repair ground circuit in the steering angle sensor.
Repair the harness between the steering angle sensor and VDCCM&H/U.
Go to step 5.
Repair the harness between the steering angle sensor and VDCCM&H/U.
Go to step 6.
Go to step 7.
CHECK OTHER DTC DETECTION.
Replace the VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).> Perform the diagnosis according to DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
Go to step 8.
Original steering angle sensor malfunction
VDC(diag)-82

AP:DTC C0071 STEERING ANGLE SENSOR MALFUNCTION

DTC DETECTING CONDITION: Defective steering angle sensor TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. NOTE: Warning light does not illuminate though problem is detected. The ABS and VDC operate normally if voltage returns. WIRING DIAGRAM:
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
* *4
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
*4 *3
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 8, 9, 10, 18, 19 AND 20 : TERMINAL No. OPTIONAL 3 ARRANGEMENT AMONG 1, 2, 5 AND 6 4 : TERMINAL No. OPTIONAL ARRANGEMENT AMONG 3, 4, 7 AND 8
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-83

Step CHECK POWER SUPPLY FOR STEERING ANGLE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from steering angle sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the steering angle sensor and chassis ground. Connector & terminal (B231) No. 4 (+) Chassis ground (): CHECK GROUND CIRCUIT OF STEERING ANGLE SENSOR. Measure the resistance between steering angle sensor and chassis ground. Connector & terminal (B231) No. 3 Chassis ground: CHECK STEERING ANGLE SENSOR. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK VDCCM&H/U. 1) Turn the ignition switch to OFF. 2) Replace the steering angle sensor. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the voltage 10 15 V? Yes Go to step 2. No Repair the power supply circuit of steering angle sensor.
Repair ground circuit in the steering angle sensor.
Go to step 4.
Go to step 5.
Go to step 6.
Original steering angle sensor malfunction
VDC(diag)-84

AQ:DTC C0072 ABNORMAL YAW RATE SENSOR OUTPUT

DTC DETECTING CONDITION: Defective yaw rate sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM:
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
*3 *4 *4 *3
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-85

Yes No VDCCM&H/U may Go to step 2. record DTC when the vehicle ran the road with banks or sandy surface (which does not mean a dirt road). CHECK YAW RATE & LATERAL G SENSOR Is the yaw rate & lateral G sen- Go to step 3. Tighten the yaw INSTALLATION. sor installation bolt tightened to rate & lateral G 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)? sensor installation bolt. CHECK OUTPUT OF YAW RATE & LATERAL Is the reading indicated on Go to step 4. Replace the yaw G SENSOR WITH SUBARU SELECT MONI- monitor display 4 4 deg/s? rate & lateral G TOR. sensor. 1) Drive the vehicle on a flat road. 2) Park the vehicle straight. 3) Select {Current Data Display & Save} in the Subaru Select Monitor. 4) Read the yaw rate output displayed on display. CHECK OUTPUT OF STEERING ANGLE Is the reading indicated on Go to step 5. Perform the cenSENSOR WITH SUBARU SELECT MONImonitor display 5 5? tering adjustment TOR. of steering wheel. 1) Drive the vehicle on a flat road. 2) Park the vehicle straight. 3) Select {Current Data Display & Save} in the Subaru Select Monitor. 4) Read the steering angle sensor output displayed on display. CHECK YAW RATE & LATERAL G SENSOR. Is the same DTC displayed? Go to step 6. Go to step 7. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Go to step 8. 1) Turn the ignition switch to OFF. VDCCM only. 2) Replace the yaw rate & lateral G sensor. <Ref. to VDC-10, 3) Clear the memory. <Ref. to VDC(diag)-23, REPLACEMENT, Clear Memory Mode.> VDC Control Mod4) Perform the Inspection Mode. <Ref. to ule and Hydraulic VDC(diag)-22, Inspection Mode.> Control Unit 5) Read the DTC. (VDCCM&H/U).> CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).> CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Malfunction is nosis according to found in original yaw rate & lateral DTC. <Ref. to VDC(diag)-34, List G sensor. of Diagnostic Trouble Code (DTC).> Step CHECK DRIVING PLACE. Check if the vehicle ran the road with banks or sandy surface (which does not mean a dirt road). Check Did the vehicle run the road with banks or sandy surface (which does not mean a dirt road)?
VDC(diag)-86

AR:DTC C0072 VOLTAGE INPUTTED TO YAW RATE SENSOR EXCEEDS SPECIFICATION

*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
* *4
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
*4 *3
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-87

Step CHECK YAW RATE & LATERAL G SENSOR POWER SUPPLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from yaw rate & lateral G sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 1 (+) Chassis ground (): CHECK YAW RATE & LATERAL G SENSOR GROUND CIRCUIT. Measure the resistance between the yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 4 Chassis ground: CHECK YAW RATE & LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the voltage 10 15 V? Yes Go to step 2. No Repair the power supply circuit of the yaw rate & lateral G sensor.
Repair the ground circuit of the yaw rate & lateral G sensor.
Replace the yaw rate & lateral G sensor.
Go to step 4.
Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-88

AS:DTC C0072 ABNORMAL YAW RATE SENSOR REFERENCE VOLTAGE

*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
*3 *4 *4 *3
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-89

Step CHECK POWER SUPPLY FOR YAW RATE & LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from yaw rate & lateral G sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 1 (+) Chassis ground (): CHECK YAW RATE & LATERAL G SENSOR GROUND CIRCUIT. Measure the resistance between the yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 4 Chassis ground: CHECK VDCCM&H/U. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the voltage 10 15 V? Yes Go to step 2. No Repair the power supply circuit of the yaw rate & lateral G sensor.
Go to step 4.
Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-90

AT:DTC C0072 CHANGE RANGE OF YAW RATE SENSOR SIGNAL IS TOO BIG
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
*3 *4 *4 *3
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
Step CHECK DRIVING PLACE. Check if the vehicle ran the road with banks or sandy surface (which does not mean a dirt road).
Yes No VDCCM&H/U may Go to step 2. record DTC when the vehicle ran the road with banks or sandy surface (which does not mean a dirt road). CHECK YAW RATE & LATERAL G SENSOR Is the yaw rate & lateral G sen- Go to step 3. Tighten the yaw INSTALLATION. sor installation bolt tightened to rate & lateral G 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)? sensor installation bolt.
Check Did the vehicle run the road with banks or sandy surface (which does not mean a dirt road)?
VDC(diag)-91

Step CHECK YAW RATE & LATERAL G SENSOR POWER SUPPLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from yaw rate & lateral G sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 1 (+) Chassis ground (): CHECK YAW RATE & LATERAL G SENSOR GROUND CIRCUIT. Measure the resistance between the yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 4 Chassis ground: CHECK OUTPUT OF YAW RATE & LATERAL G SENSOR WITH SUBARU SELECT MONITOR. 1) Drive the vehicle on a flat road. 2) Park the vehicle straight. 3) Select {Current Data Display & Save} in the Subaru Select Monitor. 4) Read the yaw rate output displayed on display. CHECK YAW RATE & LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK VDCCM&H/U. 1) Turn the ignition switch to OFF. 2) Replace the yaw rate & lateral G sensor. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Is the voltage 10 15 V? Yes Go to step 4. No Repair the power supply circuit of the yaw rate & lateral G sensor.
Is the reading indicated on Go to step 6. monitor display 4 4 deg/s?
Go to step 7.
Go to step 8.
Go to step 9.
Malfunction is found in original yaw rate & lateral G sensor.
VDC(diag)-92

AU:DTC C0073 LATERAL G SENSOR COMMUNICATION

DTC DETECTING CONDITION: Communication failure between lateral G sensor and VDCCM TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. NOTE: For the diagnostic procedure, refer to DTC C0072 YAW RATE SENSOR COMMUNICATION. <Ref. to VDC(diag)-94, DTC C0072 YAW RATE SENSOR COMMUNICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-93

AV:DTC C0072 YAW RATE SENSOR COMMUNICATION

DTC DETECTING CONDITION: Communication failure between yaw rate sensor and VDCCM TROUBLE SYMPTOM: ABS does not operate. VDC does not operate. WIRING DIAGRAM:
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
* *4
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
*4 *3
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
Step Check CHECK POWER SUPPLY FOR YAW RATE & Is the voltage 10 15 V? LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from yaw rate & lateral G sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 1 (+) Chassis ground ():
Yes Go to step 2.
No Repair the power supply circuit of the yaw rate & lateral G sensor.
VDC(diag)-94

Step CHECK YAW RATE & LATERAL G SENSOR GROUND CIRCUIT. Measure the resistance between the yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 4 Chassis ground: CHECK YAW RATE & LATERAL G SENSOR HARNESS. 1) Disconnect the connector from the VDCCM&H/U. 2) Measure the resistance between VDCCM& H/U and yaw rate & lateral G sensor. Connector & terminal (B230) No. 3 (B310) No. 10: (B230) No. 2 (B310) No. 35: CHECK GROUND SHORT CIRCUIT FOR YAW RATE & LATERAL G SENSOR HARNESS. Measure the resistance between the yaw rate & lateral G sensor and chassis ground. Connector & terminal (B230) No. 2 Chassis ground: (B230) No. 3 Chassis ground: CHECK YAW RATE & LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK YAW RATE & LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Replace the yaw rate & lateral G sensor. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC. CHECK OTHER DTC DETECTION. Check Yes Is the resistance less than 0.5 :? Go to step 3. No Repair the ground circuit of the yaw rate & lateral G sensor.
Repair the harness between yaw rate & lateral G sensor and VDCCM& H/U.
Go to step 5.
Repair the harness between yaw rate & lateral G sensor and VDCCM& H/U.
Go to step 6.
Go to step 7.
Go to step 8.
Malfunction is found in original yaw rate & lateral G sensor.
VDC(diag)-95

AW:DTC C0073 LATERAL G SENSOR OFFSET IS TOO BIG

NOTE: For the diagnostic procedure, refer to DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL. <Ref. to VDC(diag)-97, DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AX:DTC C0073 ABNORMAL LATERAL G SENSOR OUTPUT

NOTE: For the diagnostic procedure, refer to DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL. <Ref. to VDC(diag)-97, DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-96

AY:DTC C0073 EXCESSIVE LATERAL G SENSOR SIGNAL

DTC DETECTING CONDITION: Lateral G sensor malfunction TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM:
*1 *2
TWISTED PAIR LINE
SBF-6
35
10
25
* *2 *1 *2
*3 *4 *4 *3
CAN JOINT CONNECTOR
IGNITION SWITCH
B170
TWISTED PAIR LINE
TWISTED PAIR LINE
No.33
*1
E
*2 * *
B231 1 2 3 4
B230
B170 1 2 3 4 5 6 7 8
B365 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24
B310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 3 4
VDC00473
VDC(diag)-97

Step Check Yes CHECK YAW RATE & LATERAL G SENSOR Is the yaw rate & lateral G sen- Go to step 2. INSTALLATION. sor installation bolt tightened to 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)? CHECK LATERAL G SENSOR OUTPUT. 1) Park the vehicle on a level surface. 2) Select {Current Data Display & Save} in the Subaru Select Monitor. 3) Read the lateral G sensor output displayed on screen. CHECK LATERAL G SENSOR OUTPUT. 1) Turn the ignition switch to OFF. 2) Remove the yaw rate & lateral G sensors from vehicle. 3) Turn the ignition switch to ON, and select the {Current Data Display & Save} in Subaru Select Monitor. 4) Read the lateral G sensor output displayed on screen. CHECK LATERAL G SENSOR. Read the lateral G sensor output displayed on screen. Is the indicated reading on the Go to step 3. monitor display 1.5 1.5 m/s2? No Tighten the yaw rate & lateral G sensor installation bolt. Replace the yaw rate & lateral G sensor.
When the yaw rate & lateral G Go to step 4. sensor is inclined 90 to the right, is the indicated value 6.8 12.8 m/s2?
When the yaw rate & lateral G sensor is inclined 90 to the left, is the indicated value 6.8 12.8 m/s2? CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connecTurn the ignition switch to OFF. tor between VDCCM& H/U and yaw rate & lateral G sensor? CHECK VDCCM&H/U. Is the same DTC displayed? 1) Connect all connectors. 2) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 3) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 4) Read the DTC. CHECK OTHER DTC DETECTION. Is any other DTC displayed?
Go to step 5.
Repair the connec- Go to step 6. tor. Replace the Go to step 7. VDCCM only. <Ref. to VDC-10, REPLACEMENT, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diag- Temporary poor nosis according to contact occurs. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-98

AZ:DTC C0074 PRESSURE SENSOR

DTC DETECTING CONDITION: Defective pressure sensor TROUBLE SYMPTOM: ABS does not operate. VDC does not operate.
1 Step CHECK STOP LIGHT SWITCH CIRCUIT. Check stop light switch open circuit. Check Is the stop light switch circuit OK? Yes Go to step 2. No Repair the stop light switch circuit. NOTE: If there is malfunction in the stop light circuit, DTC may be memorized. Replace the VDCCM&H/U. <Ref. to VDC-7, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Replace the VDCCM&H/U. <Ref. to VDC-7, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Go to step 5.
CHECK OUTPUT OF PRESSURE SENSOR When the brake pedal is Go to step 3. WITH SUBARU SELECT MONITOR. released, is the displayed value 1) Select {Current Data Display & Save} in 40 40 bar? Subaru Select Monitor. 2) Read the pressure sensor output displayed on display. CHECK OUTPUT OF PRESSURE SENSOR WITH SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in Subaru Select Monitor. 2) Read the pressure sensor output displayed on display. CHECK PRESSURE SENSOR. 1) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 2) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 3) Read the DTC. CHECK OTHER DTC DETECTION. Go to step 4. When operating the brake pedal, does the pressure sensor output value on the display change according to the brake pedal operation?
Replace the VDCCM&H/U. <Ref. to VDC-7, VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).> Perform the diag- It results from a nosis according to temporary noise interference. DTC. <Ref. to VDC(diag)-34, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-99

BA:DTC C0081 SYSTEM FAILURE

DTC DETECTING CONDITION: VDC long time sequential control TROUBLE SYMPTOM: ABS does not operate. VDC does not operate.
1 Step CHECK POOR CONTACT IN CONNECTOR. Check Is there poor contact in the VDCCM& H/U and yaw rate & lateral G sensor connector? Is the same DTC displayed? Yes No Repair the connec- Go to step 2. tor. Replace the VDCCM&H/U. Malfunction is found in original yaw rate & lateral G sensor.
CHECK VDCCM&H/U. 1) Replace the yaw rate & lateral G sensor. 2) Connect all connectors. 3) Clear the memory. <Ref. to VDC(diag)-23, Clear Memory Mode.> 4) Perform the Inspection Mode. <Ref. to VDC(diag)-22, Inspection Mode.> 5) Read the DTC.
VDC(diag)-100


A: INSPECTION
Symptom Poor brake perforLong braking/ mance stopping distance Other probable cause Defective ABS wheel speed sensor or sensor gap Defective steering angle sensor or improper neutral position Defective yaw rate & lateral G sensor or improper installation Master cylinder Brake caliper Disc rotor Brake pipe Brake booster VDCCM&H/U Defective steering angle sensor Defective ABS wheel speed sensor or sensor gap or improper neutral position Incorrect wiring or piping connections Defective yaw rate & lateral G sensor or improper installation Brake caliper Brake pipe VDCCM&H/U Defective steering angle sensor Defective ABS wheel speed sensor or sensor gap or improper neutral position Master cylinder Defective yaw rate & lateral G Brake caliper sensor or improper installation Parking brake Brake pad Axle and wheels Brake pipe Brake pedal play VDCCM&H/U Master cylinder Brake caliper Brake pad Brake pipe Brake booster Main probable cause VDCCM&H/U Brake pad Aeration to brake line Tire specifications, tire wear and air pressures Incorrect wiring or piping connections
Wheel locks.
Brake drag
Long brake pedal stroke
Aeration to brake line Brake pedal play
Vehicle vertical pitching
VDCCM&H/U Road surface (uneven) Suspension play or fatigue (reduced damping) Incorrect wiring or piping connections
Defective ABS wheel speed sensor or sensor gap Defective steering angle sensor or improper neutral position Defective yaw rate & lateral G sensor or improper installation Defective ABS wheel speed sensor or sensor gap Defective steering angle sensor or improper neutral position Defective yaw rate & lateral G sensor or improper installation Master cylinder Disc rotor Brake pipe Axle and wheels Road with crowns or banks Suspension play or fatigue (reduced damping)
Poor brake performance
Unstable or uneven braking
VDCCM&H/U Defective ABS wheel speed sensor or sensor gap Brake caliper Brake pad Road surface (uneven) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections
VDC(diag)-101

Symptom Vibration or noise Excessive When braking brake pedal suddenly vibration When accelerating suddenly Noise from While driving on a VDCH/U slippery road Main probable cause Road surface (uneven) Incorrect wiring or piping connections Other probable cause VDCCM&H/U Brake booster Suspension play or fatigue (reduced damping) VDCCM&H/U (mount bushing) VDCCM&H/U Defective ABS wheel speed sensor or sensor gap Defective steering angle sensor Brake pipe or improper neutral position Defective yaw rate & lateral G sensor or improper installation VDCCM&H/U (mount bushing) Axle and wheels Defective ABS wheel speed sensor or sensor gap Tire specifications, tire wear and Master cylinder air pressures Brake caliper Brake pad Disc rotor Brake pipe Brake booster Suspension play or fatigue (reduced damping) Defective ABS wheel speed sensor or sensor gap Axle and wheels Brake caliper Tire specifications, tire wear and Brake pad air pressures Disc rotor Parking brake Brake pipe Suspension play or fatigue (reduced damping) Defective steering angle sensor VDCCM&H/U Defective ABS wheel speed sensor or sensor gap or improper neutral position Defective yaw rate & lateral G Master cylinder sensor or improper installation Brake caliper Brake pad Parking brake Brake pipe Incorrect wiring or piping Disc rotor Brake pipe Axle and wheels Suspension play or fatigue (reduced damping)
Noise from the rear side of vehicle Engine does not accelerate or goes into a stall when accelerating sud denly or driving on a slippery surface. Poor change-direc- Deviation to VDCCM&H/U tion-operation staright or left Defective ABS wheel speed sensor or sensor gap bility of TCS direction Defective steering angle sensor or improper neutral position Defective yaw rate & lateral G sensor or improper installation Brake caliper Brake pad Wheel alignment Road surface (uneven) Road with crowns or banks Tire specifications, tire wear and air pressures Incorrect wiring or piping connections Vehicle spin
Noise from the front side of vehicle
VDCCM&H/U Brake caliper Defective ABS wheel speed sensor or sensor gap Brake pipe Defective steering angle sensor or improper neutral position Defective yaw rate & lateral G sensor or improper installation Brake pad Tire specifications, tire wear and air pressures Incorrect wiring or piping connections
VDC(diag)-102

Symptom Steering wheel drag while driving Main probable cause VDCCM&H/U Defective ABS wheel speed sensor or sensor gap Defective steering angle sensor or improper neutral position Defective yaw rate & lateral G sensor or improper installation Incorrect wiring or piping connections Power steering system Other probable cause Brake caliper Brake pad Disc rotor Wheel alignment Road surface (uneven) Road with crowns or banks Suspension play or fatigue (reduced damping) Tire specifications, tire wear and air pressures
VDC operates while driving normally.
VDCCM&H/U Defective ABS wheel speed sensor or sensor gap Defective steering angle sensor or improper neutral position Defective yaw rate & lateral G sensor or improper installation Wheel alignment Road surface (uneven) Road with crowns or banks Suspension play or fatigue (reduced damping) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections Power steering system VDC OFF indicator light does not illu- Harness minate when the VDC OFF switch is Combination meter VDC OFF switch depressed. NOTE: When pressing VDC OFF switch for 10 seconds or more, VDC OFF indicator light goes off and cannot operate any more. When turning the ignition switch from OFF to ON, the previous status is restored.
VDC(diag)-103

VDC(diag)-104
General Description
BRAKE
A: SPECIFICATION
Model 2.5 i, -BASE, 2.5 i-LTD, 3.0 R, OUTBACK 2.5i, -BASE, -LTD, -LLB, 2.5GT-LTD, 3.0 R-LTD, 2.5GT-B OUTBACK 3.0 R -LTD, OUTBACK 2.5XT -LTD 16-inch type 17-inch type Disc (Floating type, ventilated) mm (in) 244 (4.61) 261 (10.28) mm (in) 24 294 (0.94 11.57) 30 316 (1.18 12.44) 42.8 (1.685) 2 117.8 50.5 11.0 130.0 53.5 11.0 mm (in) (4.638 1.988 0.433) (5.118 2.106 0.433) Automatic adjustment 15-inch type Disc (Floating type, solid) 238 (9.37) 10 274 (0.39 10.79) 38.1 (1.500) 92.0 33.0 9.0 82.4 33.7 9.0 (3.622 1.299 0.354) (3.244 1.327 0.354) Automatic adjustment Tandem 23.8 (15/16) Sealed type 205 (12.51) Vacuum suspended 208 + 229 (8.19 + 9.02) Dual circuit system Disc (Floating type, ventilated) 254 (10.0) 18 290 (0.71 11.42)
Front disc brake
Size Type Effective disc diameter Disc thickness Diameter Effective cylinder diameter Pad dimensions (Length Width Thickness) Clearance adjustment Size Type
Rear disc brake
Effective disc diameter Disc thickness Diameter Effective cylinder diameter Pad dimensions (Length Width Thickness) Clearance adjustment
mm (in) mm (in) mm (in) mm (in)
Master cylinder Brake booster
Type Effective diameter mm (in) Reservoir type Brake fluid reservoir capacity cm3 (cu in) Type Effective diameter mm (in)
Brake line Brake fluid CAUTION: Avoid mixing brake fluid of different brands to prevent fluid performance from degrading. When filling with brake fluid, be careful not to allow any dust to enter the reservoir. Use new SUBARU genuine brake fluid when replacing or refilling the fluid.
FMVSS No. 116, DOT3, or DOT4
BR-2
General Description
BRAKE
NOTE: Refer to PB section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Description.>
Contents Pad thickness Front brake Disc thickness Disc runout Pad thickness Rear brake (Disc type) Disc thickness Disc runout Inside diameter Lining thickness Lever stroke mm (in) mm (in) mm (in) mm (in) Except for 17-inch type 17-inch type Except for 17-inch type 17-inch type mm (in) Solid disc Ventilated disc Solid disc Ventilated disc mm (in) mm (in) mm (in) Specification Service limit 11 (0.43) 1.5 (0.059) 11 (0.43) 1.5 (0.059) 24 (0.94) 22 (0.87) 30 (1.18) 28 (1.10) 0.05 (0.0020) 9.0 (0.354) 1.5 (0.059) 9.0 (0.354) 1.5 (0.059) 10 (0.39) 8.5 (0.335) 18 (0.71) 16 (0.63) 0.05 (0.0020) 170 (6.69) 171 (6.73) 3.2 (0.126) 1.5 (0.059) 5 6 notches/200 N (20 kgf, 45 lb) Brake pedal force N (kgf, lb) Brake fluid pressure with engine stopped Brake booster Brake fluid pressure with engine running and vacuum pressure at 66.7 kPa (500 mmHg, 19.69 inHg) 147 (15, 33) 294 (30, 66) 147 (15, 33) 294 (30, 66) Fluid pressure kPa (kgf/cm2, psi) 545 (6, 79) 1,564 (16, 227) 6,003 (61, 870) 11,273 (115, 1,635)
Parking brake
Brake pedal
Free play
mm (in)
0.5 2 (0.02 0.08) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lb)]
BR-3
General Description
BRAKE
B: COMPONENT
1. FRONT DISC BRAKE
T2 (2)
T1
(3) T3 (1) (4)
(5) (6) (7) (A )
(9) (8) (10) (1 1 ) (1 2 ) (1 4 ) (1 3) (12) (11) ( 16) (11) (12) (1 5 ) (14) (13) (12) (11 ) (B) (17) (4)
BR-00332
(A) (1) (2) (3) (4) (5) (6) (7) (8)
16-inch type Caliper body Air bleeder screw Guide pin (black) Pin boot Piston seal Piston Piston boot Lock pin (silver)
(B) (9) (10) (11) (12) (13) (14) (15)
17-inch type Support Pad clip Outer shim Inner shim Pad (outside) Pad (inside) Disc rotor (16) (17) Disc cover Bushing
BR-4
General Description
BRAKE
2. REAR DISC BRAKE

(34) T2 (2) T1 (3) T3 (3 5 ) (1) (4)
(5) (6) (7) (8)
(36) (14) (12) (9) (10) (4) (11) (14) T4 (17)
(1 6 ) (11) (13) (18) (19) (20)
(21) (24)
(23)
(25) (26) (27) (22) (28) (3 2 ) (31) (30) (15) BR-00539 (29)
(33)
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Caliper body Air bleeder screw Guide pin (black) Pin boot Piston seal Piston Piston boot Support Lock pin (silver) Bushing Pad clip Inner pad Outer pad Shim
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Shoe hold-down pin Cover Back plate Retainer Spring washer Parking brake lever Parking brake shoe (secondary) Parking brake shoe (primary) Strut Strut shoe spring Shoe guide plate Secondary shoe return spring Primary shoe return spring Adjusting spring
(29) (30) (31) (32) (33) (34) (35) (36)
Adjuster Shoe hold-down cup Shoe hold-down spring Disc rotor (solid type) Disc rotor (ventilated type) Bolt (for solid disc brake) Bolt (for ventilated disc brake) Shim (for solid disc brake)
BR-5
General Description
BRAKE
3. MASTER CYLINDER
(1)
(2)
(10)
(3)
(9)
(8)
(4) (5) (6)
(11)
(7)
BR-00371
(1) (2) (3) (4) (5)
Cap Filter Reservoir tank C-ring Primary piston
(6) (7) (8) (9) (10)
Secondary piston Cylinder body Cylinder pin Seal Pin
(11)
O-ring
BR-6
General Description
BRAKE
4. FRONT BRAKE PIPES AND HOSES

(B) (8) (2) T2 T1 T1 (1) T3 T1
T2
T4 (A)
(5)
(9) (8) (2) T2 T1 T1 (1) T1 T2 T2 T2 (6) T4 (10) T3 (6) (3) (4) T1 T3 (5)
(7) T1 (5) (9) T4 (3) (4) (6) T1 T2 T2 (6) BR-00581 T4 T1 (5)
(A)
Model with ABS
(B)
Model with vehicle dynamics control (VDC) ABS control module and hydraulic control unit (ABSCM&H/U) Bracket Master cylinder VDC control module and hydraulic control unit (VDCCM&H/U) Tightening torque:Nm (kgf-m, ft-lb) T1: 15 (1.5, 10.8) T2: 18 (1.8, 13.0) T3: 19 (1.9, 14.0) T4: 33 (3.4, 24.3)
(1) (2) (3) (4) (5) (6)
Front brake pipe ASSY Two-way connector Front brake hose RH Front brake hose LH Clamp Gasket
(7) (8) (9) (10)
BR-7
General Description
BRAKE
5. CENTER AND REAR BRAKE PIPES AND HOSES

T3 (11) (8) (6) (10) (10) T1 (12) T2 (3) T1 T1 (2) T2 T3 T1 T1 T1 (1) (5) T1 (10) (7) (10) (4) (10) T3 T3 T2 (11) (9) (11) T2 (11)
(10)
BR-00337
(1) (2) (3) (4) (5) (6)
Center brake pipe ASSY Two-way connector Rear brake pipe ASSY Rear brake hose RH Rear brake hose LH Rear brake pipe RH
(7) (8) (9) (10) (11) (12)
Rear brake pipe LH Rear brake hose rear RH Rear brake hose rear LH Clamp Gasket Bracket
6. BRAKE BOOSTER
(1) BR-00600
(1)
Brake booster
BR-8
General Description
BRAKE
7. BRAKE PEDAL
MT model
T2
T2 (1) T2 T2
(2)
T1 (6)
T1 T1
(3)
(4) (5)
BR-00595
(1) (2) (3)
Brake pedal ASSY Stop light switch Brake pedal pad
(4) (5) (6)
Clutch pedal Clutch pedal pad Clutch switch
BR-9
General Description
BRAKE
AT model
T2
(1)
(2) T1
T2
T1
(3)
BR-00338
(1) (2)
Brake pedal ASSY Stop light switch
(3)
Brake pedal pad
BR-10
General Description
BRAKE
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers. Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points.
D: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME Snap ring pliers REMARKS Used for removing and installing snap rings.
BR-11
Front Brake Pad

BRAKE
2. Front Brake Pad

A: REMOVAL
1. 16-INCH TYPE
1) Lift up the vehicle, and remove the front wheels. 2) Remove the caliper bolt.
2) Apply a thin coat of Molykote AS880N (Part No. K0779YA010) or grease contained in the pad kit to both surfaces of the pad inner shim.
BR-00601
3) Install the pad to support. 4) Install the caliper body to the support.
BR-00339
3) Raise the caliper body and support it. NOTE: Do not disconnect the brake hose from the caliper body. 4) Remove the pad.
2. 17-INCH TYPE
1) Apply a thin coat of Molykote M7439 (Part No. K0777YA000) or grease contained in the pad kit to the pad clip.
BR-00012
BR-00596
2. 17-INCH TYPE
Refer to 16-inch type. <Ref. to BR-12, 16-INCH TYPE, REMOVAL, Front Brake Pad.>
B: INSTALLATION
1. 16-INCH TYPE
BR-00601
BR-00596
BR-12
Front Brake Pad

BRAKE
3) Install the pad to support. NOTE: Install the pad indicator in proper direction.
(1)
4) Install the caliper body to the support. Tightening torque: 27 Nm (2.8 kgf-m, 19.9 ft-lb)
C: INSPECTION
1. 16-INCH TYPE
Check thickness A of the pad.
(6)
(2)
(6) (3) (6) A
BR-00360 (5) (4)
Pad thickness mm (in)
Standard Wear limit
11 (0.43) 1.5 (0.059)
(6) BR-00586
(1) (2) (3) (4) (5) (6)
LH IN LH OUT RH IN RH OUT Pad indicator Pad return spring
NOTE: Always replace the pads of both wheels and both sides as a set. Replace pad clips if they are twisted or worn. Replace the pad if there is oil or grease on it.
2. 17-INCH TYPE
Check the pad thickness A.
CAUTION: Be sure to install so that the pad return spring faces the input side of the direction of brake rotor rotation, as shown in the figure. Correctly install the pad return spring to the supporting surface of the pad clip as shown in the figure. If the pad return spring is deformed or damaged, replace the brake pad.
BR-00360
Pad thickness mm (in)
Standard Wear limit
11 (0.43) 1.5 (0.059)
NOTE: Always replace the pads of both wheels and both sides as a set. Replace the pad if there is oil or grease on it.
(1) (2) (3) BR-00483
(1) Pad return spring (2) Supporting surface of pad clip (3) Direction of brake rotor rotation
BR-13
Front Disc Rotor

BRAKE
3. Front Disc Rotor

A: REMOVAL
1. 16-INCH TYPE
1) Lift up the vehicle, and remove the front wheels. 2) Remove the caliper body and the support from housing, and suspend it from the strut using a wire.
C: INSPECTION
1) Check the front wheel bearing play and axle hub runout before the inspection of disc rotor runout limit. <Ref. to DS-16, INSPECTION, Front Axle.> 2) Secure the disc rotor by tightening the five wheel nuts. 3) Set a dial gauge 10 mm (0.39 in) inward from the disc rotor outer circumference. Rotate the disc rotor to check runout. If the disc rotor runout exceeds the limit, resurface the disc rotor. After grinding, check the thickness of the disc rotor according to the procedure in step 4).
BR-00017
3) Remove the disc rotor. NOTE: If it is difficult to remove the disc rotor from the hub, drive an 8 mm bolt into the threaded section (B) of the rotor, then remove the rotor.
BR-00019
Disc rotor runout limit: 0.05 mm (0.0020 in) 4) Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor exceeds the service limit, replace with a new disc rotor.
B A BR-00018
4) Remove mud and foreign matter from the caliper body assembly and the support.
2. 17-INCH TYPE
Refer to 16-inch type. <Ref. to BR-14, 16-INCH TYPE, REMOVAL, Front Disc Rotor.>
B A BR-00018
B: INSTALLATION
1) Install the disc rotor. 2) Install the caliper body and the support to housing. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 3) Install the front wheels.
Standard Disc rotor 16s thickness A mm (in) 17s 24 (0.94) 30 (1.18) Limit 22 (0.87) 28 (1.10)
Disc rotor outer diameter 294 (11.57) 316 (12.44)
BR-14
Front Disc Brake Assembly

BRAKE
4. Front Disc Brake Assembly

A: REMOVAL
1. 16-INCH TYPE
CAUTION: Do not allow brake fluid to come in contact with vehicle body. If it does, wash off with water and wipe away completely. 1) Lift up the vehicle, and remove the front wheels. 2) Remove the union bolt, and disconnect the brake hose from the caliper body assembly.
2. 17-INCH TYPE
Refer to 16-inch type. <Ref. to BR-15, 16-INCH TYPE, REMOVAL, Front Disc Brake Assembly.>
B: INSTALLATION
1. 16-INCH TYPE
1) Apply a thin coat of Molykote M7439 (Part No. K0777YA000) or grease contained in the pad kit to the support.
BR-00597
2) Install the support to the housing.

BR-00021
3) Remove the bolt securing the lock pin to caliper body.
Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 3) Apply a thin coat of Molykote M7439 (Part No. K0777YA000) or grease contained in the pad kit to the pad clip.
BR-00022
4) Raise the caliper body, and then move it toward vehicle center to separate it from the support. 5) Remove the support from housing. NOTE: Remove the support only when replacing the rotor or support. It is not necessary to remove it when servicing the caliper body assembly.
BR-00596
BR-00601
BR-00023
5) Install the pad to support. 6) Install the caliper body to the support. Tightening torque: 27 Nm (2.8 kgf-m, 19.9 ft-lb)
6) Remove mud and foreign matter from the caliper body assembly and the support.
BR-15

BRAKE
7) Connect the brake hose using a new brake hose gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 8) Bleed air from the brake system.
5) Install the pad to support. NOTE: Install the pad indicator in proper direction.
(1)
2. 17-INCH TYPE
(6) (2)
(6) (3) (6)
(5) (4) BR-00597
2) Install the support to the housing. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 3) Apply a thin coat of Molykote M7439 (Part No. K0777YA000) or grease contained in the pad kit to the pad clip.
(6) BR-00586
(1) (2) (3) (4) (5) (6)
LH IN LH OUT RH IN RH OUT Pad indicator Pad return spring
BR-00596
CAUTION: Be sure to install so that the pad return spring faces the input side of the direction of brake rotor rotation, as shown in the figure. Correctly install the pad return spring to the supporting surface of the pad clip as shown in the figure. If the pad return spring is deformed or damaged, replace the brake pad.
(1) BR-00601 (2) (3) BR-00483
(1) Pad return spring (2) Supporting surface of pad clip (3) Direction of brake rotor rotation
BR-16

BRAKE
6) Install the caliper body to the support. 7) Connect the brake hose using a new brake hose gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 8) Bleed air from the brake system.
5) Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove.
(1)
C: DISASSEMBLY
1. 16-INCH TYPE
1) Remove mud and foreign matter from the caliper body assembly and the support. CAUTION: Be careful not to allow foreign matter to enter the brake hose connector. 2) Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged. 3) Gradually apply compressed air via the brake hose installation hole to push the piston out.
BR-00027
(1) Piston seal
6) Remove the guide pin and boot from caliper body.
2. 17-INCH TYPE
Refer to 16-inch type. <Ref. to BR-17, 16-INCH TYPE, DISASSEMBLY, Front Disc Brake Assembly.>
(1) BR-00026
(1) Place a wooden block of 30 mm (1.18 in) width.
4) Remove the piston boot.
BR-00240
BR-17

BRAKE
D: ASSEMBLY
1. 16-INCH TYPE
1) Clean the inside of the caliper body using brake fluid. 2) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove. 3) Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston. 4) Apply grease contained in the piston seal kit to the boot, and install it to the groove at the end of the cylinder. 5) Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder.
(2)
8) Insert the lock pin and guide pin boot into the support.
: (3) (1) (2)
BR-00362
(1) Pin boot (2) Lock pin or guide pin (3) Grease applied area
(1)
CAUTION: After inserting the lock pin and guide pin into the specified locations, check by hand that the pin moves and slides smoothly with no abnormalities when it reaches the end.
2. 17-INCH TYPE
BR-00242
Refer to 16-inch type. <Ref. to BR-18, 16-INCH TYPE, ASSEMBLY, Front Disc Brake Assembly.>
(1) Piston (2) Piston boot
E: INSPECTION
1) Repair or replace the faulty parts. 2) Check the caliper body and piston for uneven wear, damage or rust. 3) Check the rubber parts for damage or deterioration.
6) Position the boot in the grooves on cylinder and piston.

(3) (4) (2) (1)
BR-00243
(1) (2) (3) (4)
Piston Piston boot Caliper body Piston seal
7) Apply grease contained in the piston seal kit to the lock pin, guide pin outer surface, cylinder inner surface, and boot grooves.
BR-18
Rear Brake Pad

BRAKE
5. Rear Brake Pad

A: REMOVAL
1) Lift up the vehicle, and remove the rear wheels. 2) Remove the caliper bolt.
B: INSTALLATION
BR-00599 BR-00344
3) Raise the caliper body and support it. NOTE: Do not disconnect the brake hose from the caliper body. 4) Remove the pads.
2) Apply a thin coat of Molykote AS880N (Part No. K0779YA010) or grease contained in the pad kit to the contact surface between the pad and shim. 3) Install the pad to support. 4) Install the caliper body to the support. Tightening torque: Solid disc brake model 27 Nm (2.8 kgf-m, 19.9 ft-lb) Ventilated disc brake model 37 Nm (3.7 kgf-m, 27.2 ft-lb)
C: INSPECTION
Check the pad thickness A.
BR-00032
A BR-00016
Type of disc rotor Pad thickness Standard mm (in) Wear limit
Solid 9.0 (0.35) 1.5 (0.059)
Ventilated 9.0 (0.35) 1.5 (0.059)
NOTE: Always replace the pads of both wheels and both sides as a set. Replace pad clips if they are twisted or worn. A wear indicator is installed on the inner disc brake pad. If the pad is worn to the limit, the end of wear indicator contacts disc rotor, and a squeaking sound is heard as the wheel rotates. If the sound is heard, replace the pad. Replace the pad if there is oil or grease on it.
BR-19
Rear Disc Rotor

BRAKE
6. Rear Disc Rotor

A: REMOVAL
1) Lift up the vehicle, then remove the rear wheels. 2) Release the parking brake. 3) Remove the two mounting bolts, and remove the disc brake assembly.
(2) If it is difficult to remove the disc rotor from the hub, drive an 8 mm bolt into the threads B of the rotor, then remove the rotor.
B A BR-00036
B: INSTALLATION
BR-00346
4) Suspend the disc brake assembly so that the hose is not stretched. 5) Remove the disc rotor. NOTE: If it is difficult to remove the disc rotor, perform the following two methods in order. (1) Turn the adjusting screw using a flat tip screwdriver until the brake shoe is far enough away to allow removal of the disc rotor.
(2) (3)
1) Install in the reverse order of removal. 2) Adjust the parking brake. <Ref. to PB-8, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
(1) (4) BR-00155
(1) (2) (3) (4)
Adjusting screw Cover Flat tip screwdriver Back plate
BR-20
Rear Disc Rotor

BRAKE
C: INSPECTION
1) Check the rear wheel bearing play and axle hub runout before inspecting the disc rotor runout limit. <Ref. to DS-21, INSPECTION, Rear Hub Unit Bearing.> 2) Secure the disc rotor by tightening the five wheel nuts. 3) Set a dial gauge 10 mm (0.39 in) inward from the disc rotor outer circumference. Rotate the disc rotor to check runout. If the disc rotor runout exceeds the limit, resurface the disc rotor. After grinding, check the thickness of the disc rotor according to the procedure in step 4).
BR-00037
Disc rotor runout limit: 0.05 mm (0.0020 in) 4) Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of the disc rotor exceeds the service limit, replace with a new disc rotor.
B A BR-00036
Disc rotor thickness A Solid disc mm (in) Ventilated disc
Standard 10 (0.39) 18 (0.71)
Limit 8.5 (0.335) 16 (0.63)
Disc outer dia. 274 (10.79) 290 (11.42)
BR-21
Rear Disc Brake Assembly

BRAKE
7. Rear Disc Brake Assembly

A: REMOVAL
CAUTION: Do not allow brake fluid to come in contact with vehicle body. If it does, wash off with water and wipe away completely. 1) Lift up the vehicle, then remove the rear wheels. 2) Disconnect the brake hose from caliper body assembly. 3) Remove the caliper lower bolt.
B: INSTALLATION
BR-00597
2) Install the support to the housing. Tightening torque: 66 Nm (6.7 kgf-m, 48.7 ft-lb) 3) Apply a thin coat of Molykote M7439 (Part No. K0777YA000) or grease contained in the pad kit to the pad clip.
BR-00347
4) Raise the caliper body, and then move it toward vehicle center to separate it from the support. 5) Remove the support from housing. NOTE: Remove the support only when replacing the rotor or support. It is not necessary to remove it when servicing the caliper body assembly. 6) Remove mud and foreign matter from the caliper body assembly and the support. CAUTION: Be careful not to allow foreign matter to enter the brake hose connector.
BR-00599
4) Apply a thin coat of Molykote AS880N (Part No. K0779YA010) or grease contained in the pad kit to the contact surface between the pad and shim. 5) Install the pad to support. 6) Install the caliper body to the support. Tightening torque: Solid disc brake model 27 Nm (2.8 kgf-m, 19.9 ft-lb) Ventilated disc brake model 37 Nm (3.7 kgf-m, 27.2 ft-lb) 7) Connect the brake hose using a new brake hose gasket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 8) Bleed air from the brake system.
BR-22

BRAKE
C: DISASSEMBLY
1) Remove the piston boot.
D: ASSEMBLY
1) Clean the inside of the caliper body using brake fluid. 2) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove. 3) Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston. 4) Apply grease contained in the piston seal kit to the boot, and install it to the groove at the end of the cylinder. 5) Insert the piston into cylinder.
BR-00041
2) Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged. 3) Gradually apply compressed air via the brake hose installation hole to push the piston out.
CAUTION: Do not force the piston into cylinder. 6) Position the boot in the grooves on piston and cylinder.
(3) (4) (2) (1)
BR-00243 (1) BR-00042
(1) Place a wooden block of 30 mm (1.18 in) width.
(1) (2) (3) (4)
Piston Piston boot Caliper body Piston seal
4) Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove.
7) Apply grease contained in the piston seal kit to the guide pin, outer periphery, sleeve periphery, cylinder inner surface, and boot grooves.
: (3) (1) (2)
BR-00362 BR-00043
5) Remove the lock pin sleeve and boot from caliper body. 6) Remove the guide pin boot.
(1) Pin boot (2) Lock pin or guide pin (3) Grease applied area
8) Insert the guide pin boot to the support. 9) Install the lock pin boot to the support, and then insert the lock pin sleeve into the specified position. CAUTION: Insert the lock pin and guide pin into position, and make sure that they slide and seat properly.
BR-23

BRAKE
E: INSPECTION
1) Repair or replace the faulty parts. 2) Check the caliper body and piston for uneven wear, damage or rust. 3) Check the rubber parts for damage or deterioration.
BR-24
Master Cylinder
BRAKE
8. Master Cylinder
A: REMOVAL
CAUTION: Do not allow brake fluid to come in contact with vehicle body. If it does, wash off with water and wipe away completely. 1) Drain brake fluid from the reservoir tank completely. 2) Disconnect the harness connector of the fluid level gauge. 3) Remove the brake pipe from the master cylinder. 4) Remove the master cylinder mounting nuts, and remove the master cylinder from the brake booster.
C: REPLACEMENT
1) Remove mud and dirt from the surface of brake master cylinder. 2) Secure the master cylinder in a vise. NOTE: To avoid damaging the master cylinder, place between aluminum plates or other material when holding with a vise. 3) Remove the pin which secures the master cylinder and reservoir tank, then remove the reservoir tank and seal.
B: INSTALLATION
1) Replace the O-ring for the master cylinder with a new part. CAUTION: Be careful not to install the O-ring in the wrong location.
BR-00364 (3) (2) (1)
4) While pushing in the primary piston, remove the C-ring using pliers.
BR-00363
(1) Primary piston (2) O-ring (3) Do not install the O-ring on this groove.
BR-00169
2) Install in the reverse order of removal. Tightening torque: Master cylinder mounting nut 13 Nm (1.3 kgf-m, 9.6 ft-lb) Piping flare nut Model with ABS 15 Nm (1.5 kgf-m, 10.8 ft-lb) Model with VDC 19 Nm (1.9 kgf-m, 14.0 ft-lb) CAUTION: Be sure to use recommended brake fluid. 3) Bleed air from brake system. <Ref. to BR-32, PROCEDURE, Air Bleeding.>
5) While pushing in the primary piston, remove the straight pin from the port on the reservoir tank attachment location using a magnet pick-up tool.
(1)
BR-00069
(1) Straight pin
6) Extract the primary piston assembly and secondary piston assembly straight out while taking care not to scratch the inner surface of the cylinder.
BR-25
Master Cylinder
BRAKE
7) Clean the inside of master cylinder with brake fluid. Check the inside of the cylinder for damage, deformation and wear. Replace the master cylinder as assembly if faulty. 8) Apply brake fluid to the inner surface of master cylinder and piston assembly. 9) Make sure that the inner surface of master cylinder and the piston assembly are free of foreign matter. Install the primary piston assembly and the secondary piston assembly to master cylinder, while taking care not to scratch the master cylinder inner surface. 10) While pushing-in the primary piston, install the cylinder pin. 11) While pushing-in the primary piston, install the C-ring to the groove using pliers.
14) Replace the O-ring for the master cylinder with a new part.
(3) (2) (1)
BR-00363
D: INSPECTION
Inspect for oil leakage from the master cylinder. NOTE: After replacing the piston kit, if an oil leakage is found even though there is no damage or scratches on the inside of the cylinder, the master cylinder inner wall may be worn. In this case, replace the master cylinder as an assembly.
BR-00169
CAUTION: Make sure the C-ring is installed to the groove securely. 12) Install the seal to reservoir tank.
(1)
BR-00072
(1) Seal
13) Install the reservoir tank to the master cylinder, and secure with pin.
BR-26
Brake Booster
BRAKE
9. Brake Booster
A: REMOVAL
1) Remove or disconnect the following parts in the engine compartment. (1) Disconnect the connector of brake fluid level gauge. (2) Remove the brake pipe from the master cylinder. (3) Remove the master cylinder installation nut. (4) Disconnect the vacuum hose from brake booster. 2) Remove the following parts from the pedal bracket. (1) Snap pin and clevis pin (2) Four brake booster installation nuts
3) Remove the brake booster while avoiding the brake pipe. NOTE: Make sure that the booster shell and vacuum pipe are not subject to strong impacts. Be careful not to drop the brake booster. If the booster is dropped, replace it. Use special care when handling the operating rod. If excessive force is applied to the operating rod, the angle may change by r3, and it may result in damage to power piston cylinder. Be careful when placing the brake booster on floor. Do not change the push rod length. CAUTION: Do not disassemble the brake booster. If external force is applied from above when brake booster is placed in this position, the resin portion as indicated by P may become damaged.
(1)
(1)
(2) BR-00075 (3)
(1) Force
(4) BR-00073
(1) (2) (3) (4)
Nut Clevis pin Snap pin Operating rod
BR-27
Brake Booster
BRAKE
B: INSTALLATION
1) Check and adjust the operating rod of the brake booster. Specification L: 136.5 mm (5.38 in) If it is out of specification, adjust it with the brake booster operating rod.
L
5) After replacing the O-ring, install the master cylinder to brake booster.
(3) (2) (1)
BR-00363
BR-00076
2) Mount the brake booster in position. 3) Connect the operating rod to brake pedal with clevis pin and snap pin.
6) Connect the brake pipes to the master cylinder. 7) Connect the connector of the brake fluid level gauge. 8) Measure the clearance between the threaded end of the stop light switch and the stopper. If it is not within the specification, adjust it by adjusting the position of the stop light switch. <Ref. to BR40, ADJUSTMENT, Stop Light Switch.> CAUTION: Be careful not to rotate the stop light switch. Stop light switch clearance A: 0.3 mm (0.012 in)
(1)
A (2) (3)
BR-00079 (4) BR-00073
9) Apply grease to the operating rod connecting pin to prevent it from wear. 10) Bleed air from brake system. Tightening torque (air bleeder screw): 8 Nm (0.8 kgf-m, 5.8 ft-lb) 11) Perform a road test to make sure the brakes do not drag.
(1) (2) (3) (4)
Nut Clevis pin Snap pin Operating rod
NOTE: Apply a thin coat of SUNLIGHT 2 (Part No. 003602010) to the clevis pin. 4) Connect the vacuum hose to the brake booster.
BR-28
Brake Booster
BRAKE
C: INSPECTION
1. OPERATION CHECK (WITHOUT GAUGES)
CAUTION: When checking operation, be sure to apply the parking brake securely. Check without gauges This method can not determine exactly what part is defective. But it is possible to identify the outline of the defect by performing the check according to the following procedures. Air tightness check Start the engine, and idle it for 1 to 2 minutes, then turn it OFF. Depress the brake pedal several times applying the normal pedal force. The pedal stroke should be the longest at the 1st depression, and it should become shorter at each successive depression. If no change occurs in the pedal height when pressed, the brake booster is faulty.
(1) (2)
Operation check 1) While the engine is OFF, depress the brake pedal several times applying the same pedal force, to check for a change in pedal height.
(1) (2)
BR-00081
(1) When engine is stopped (2) When engine is started
2) With the brake pedal depressed, start the engine. 3) As the engine starts, the brake pedal should move slowly toward the floor. If the pedal height does not change, the brake booster is faulty. NOTE: If faulty, check precisely with gauges. Loaded air tightness check
(5) (4) (3) BR-00080
(1) (2) (3) (4) (5)
Normal operation Not OK 1st 2nd 3rd
Depress the brake pedal while the engine is running, and turn the engine to OFF while the pedal is depressed. Keep the pedal depressed for 30 seconds. If the pedal height does not change, the function of brake booster is normal. If the pedal height increases, it is faulty. NOTE: If faulty, check precisely with gauges.
2. OPERATION CHECK (WITH GAUGES)

CAUTION: When checking operation, be sure to apply the parking brake securely.
NOTE: In case of defective operation, inspect the condition of the check valve and vacuum hose as well. Replace them if faulty, and perform the test again. If no improvement is observed, check precisely with gauges.
BR-29
Brake Booster
BRAKE
Check with gauges Connect the gauge as shown in the figure. After bleeding air from the pressure gauge, perform the checks.
(1) (2) (3) (4) (5)
Loaded air tightness check 1) Start the engine and depress the brake pedal with a pedal force of 196 N (20 kgf, 44 lb). Keep the engine running and keep the pedal pressed until a vacuum of point B = 66.7 kPa (500 mmHg, 19.69 inHg) is indicated on the vacuum gauge.
(1) (2) B (3)
BR-00082
(4)
(1) (2) (3) (4) (5)
Pressure gauge Vacuum gauge Adapter hose Vacuum hose Pedal force gauge
BR-00084
(1) (2) (3) (4)
Pressure gauge Vacuum gauge Pedal force gauge Depressed
Air tightness check 1) Start the engine and keep it running until vacuum pressure indicates point A of the vacuum gauge = 66.7 kPa (500 mmHg, 19.69 inHg). Do not depress the brake pedal at this time.
(1) (2) A
2) Stop the engine and check the vacuum gauge. If the vacuum pressure drop within 15 seconds after stopping the engine is 3.3 kPa (25 mmHg, 0.98 inHg) or less, the function of brake booster is normal. If defective, refer to AIR TIGHTNESS CHECK. <Ref. to BR-29, INSPECTION, Brake Booster.> 3) If the brake booster is faulty, replace it with a new part. Lack of boost action check Turn the engine OFF, and set the value of the vacuum gauge to 0. Then, check the fluid pressure when the brake pedal is depressed. The pressure must be greater than the specification listed.
Brake pedal operation force N (kgf, lb) Fluid pressure kPa (kg/cm2, psi) 147 (15, 33) 545 (6, 79) 294 (30, 66) 1,564 (16, 227)
BR-00083
(1) Pressure gauge (2) Vacuum gauge
2) Stop the engine and check the gauge. If the vacuum pressure drop within 15 seconds after stopping the engine is 3.3 kPa (25 mmHg, 0.98 inHg) or less, the function of brake booster is normal. If faulty, the cause may be one of the following. Check valve malfunction Leak from vacuum hose Leak from shell joint section or stud bolt welded section Damaged diaphragm Leak from valve body seal and bearing section Leak from plate and seal assembly section Leak from poppet valve assembly section
Boosting action check Set the vacuum gauge reading to 66.7 kPa (500 mmHg, 19.69 inHg) with the engine running. Then, check the fluid pressure when the brake pedal is depressed. The pressure must be greater than the specification listed.
Brake pedal operation force N (kgf, lb) Fluid pressure kPa (kg/cm2, psi) 147 (15, 33) 6,003 (61, 871) 294 (30, 66) 11,273 (115, 1,635)
BR-30
Brake Fluid
BRAKE
10.Brake Fluid
A: INSPECTION
1) Check that the brake fluid level is between MIN and MAX. If out of the specified range, refill or drain fluid. If the fluid level is close to MIN, check the brake pad for wear and refill the fluid. 2) Check the fluid for discoloration. If the fluid color has changed excessively, drain the fluid and refill with new fluid.
B: REPLACEMENT
CAUTION: Do not let brake fluid come into contact with the painted surface of the vehicle body. Wash away with water immediately and wipe off if it is spilled by accident. Avoid mixing brake fluid of different brands to prevent fluid performance from degrading. Be careful not to allow dirt or dust to enter the reservoir tank. NOTE: During the operation, keep the reservoir tank filled with brake fluid to eliminate entry of air. Operate the brake pedal slowly. For convenience and safety, two people should do the work. The required amount of brake fluid is approximately 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for the entire brake system. 1) Lift up the vehicle and set rigid racks at the specified locations, or keep the vehicle lifted. 2) Remove both the front and rear wheels. 3) Drain brake fluid from the reservoir tank. 4) Refill the reservoir tank with the recommended brake fluid. Recommended brake fluid: Refer to the specification of General Description. <Ref. to BR-2, SPECIFICATION, General Description.> Perform the same procedure as for bleeding the brake line, until new brake fluid comes out from vinyl tube. <Ref. to BR-32, PROCEDURE, Air Bleeding.>
BR-31
Air Bleeding
BRAKE
11.Air Bleeding
A: PROCEDURE
CAUTION: Do not let brake fluid come into contact with the painted surface of the vehicle body. Wash away with water immediately and wipe off if it is spilled by accident. Avoid mixing brake fluid of different brands to prevent fluid performance from degrading. Be careful not to allow dirt or dust to enter the reservoir tank.
8) Install the brake pipe to the master cylinder. Tightening torque: Model with ABS 15 Nm (1.5 kgf-m, 10.8 ft-lb) Model with VDC 19 Nm (1.9 kgf-m, 14.0 ft-lb) 9) Bleed air from the brake line. <Ref. to BR-32, BRAKE LINE, PROCEDURE, Air Bleeding.>
2. BRAKE LINE
1) When the master cylinder is disassembled or the reservoir tank is empty, bleed the master cylinder before bleeding the brake line. <Ref. to BR-32, MASTER CYLINDER, PROCEDURE, Air Bleeding.> 2) Fill the reservoir tank of the master cylinder with brake fluid. NOTE: While bleeding air, keep the reservoir tank filled with brake fluid to prevent entry of air. 3) Attach one end of the vinyl tube to the air bleeder and the other end to the brake fluid container.
1. MASTER CYLINDER
NOTE: When the master cylinder is disassembled or the reservoir tank is empty, bleed the master cylinder. If bleeding of the master cylinder is not necessary, omit the following procedures, and perform bleeding of the brake line. <Ref. to BR-32, BRAKE LINE, PROCEDURE, Air Bleeding.> 1) Fill the reservoir tank of the master cylinder with brake fluid. NOTE: While bleeding air, keep the reservoir tank filled with brake fluid to prevent entry of air. 2) Disconnect the brake line at primary and secondary sides. 3) Wrap the master cylinder with a plastic bag. 4) Depress the brake pedal slowly and hold it.
BR-00087
BR-00090
5) Plug the outlet plug with your finger, and then release the brake pedal.
4) Depress the brake pedal several times, and hold it. 5) Loosen the air bleeder screw to drain brake fluid. Tighten the air bleeder quickly, and release the brake pedal. 6) Repeat the steps 4) to 5) until there are no more air bubbles in the vinyl tube. 7) Repeat the steps from 2) to 6) above to bleed air from each wheel. NOTE: Perform the operation in the order from the farthest wheel cylinder from the master cylinder. 8) Securely tighten the air bleeder screws. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb) 9) Check that there are no brake fluid leaks in the entire system.
BR-00091
6) Repeat steps 4) and 5) several times. 7) Remove the plastic bag.
BR-32
Air Bleeding
BRAKE
10) Check the pedal stroke. Run the engine at idle after warming up the engine, and depress the brake pedal with a force of 500 N (51 kgf, 112 lb). Measure the distance between the brake pedal and steering wheel. Release the pedal, and measure the distance between pedal and steering wheel again.
(1)
1 2 1 2
(2) BR-00094
(1) Steering wheel (2) Toe board
Specification of pedal stroke: When depressing the pedal with a force of 500 N (51 kgf, 112 lbf). 95 mm (3.74 in) or less 11) If the distance is more than specification, there is a possibility of air being caught in the brake line. Bleed the brake line of all air until the pedal stroke meets the specification. 12) Operate the hydraulic control unit in the sequence control mode. <Ref. to ABS-10, ABS Sequence Control.> 13) Check the pedal stroke again. 14) If the distance is more than specification, there is a possibility of air being caught in the hydraulic unit. Repeat above steps 2) to 9) until the pedal stroke meets the specification. 15) Fill the reservoir tank with brake fluid up to the MAX level. 16) Test run the vehicle and ensure that the brakes operate normally.
BR-33
Brake Hose
BRAKE
12.Brake Hose
A: REMOVAL
1. FRONT BRAKE HOSE
1) Separate the brake pipe from brake hose using a flare nut wrench. 2) Remove the clamp, the strut mount bolts, and union bolt.
(1)
3) Remove the clamp, and then remove the brake hose.
(1)
(2)
BR-00349 (2)
(1) Brake pipe (2) Brake hose clamp
BR-00095
(1)
(1) Brake hose (2) Brake pipe
2. REAR BRAKE HOSE

1) Remove the union bolt from the rear brake caliper.
(2) (3) BR-00350
(1)
(1) Brake pipe (2) Brake hose (3) Brake hose clamp
BR-00348
(1) Brake hose
2) Separate the brake pipe from brake hose using a flare nut wrench.
BR-34
Brake Hose
BRAKE
B: INSTALLATION
1. FRONT BRAKE HOSE
1) Secure the brake hose to strut mount. Tightening torque: 33 Nm (3.4 kgf-m, 24.3 ft-lb) 2) Install the brake hose to the caliper using a new gasket. Tightening torque (union bolt): 18 Nm (1.8 kgf-m, 13.0 ft-lb)
(1) Brake pipe (2) Brake hose clamp
BR-00349 (1) (2)
3) Install the brake hose to rear brake caliper using a new gasket. Tightening torque (union bolt): 18 Nm (1.8 kgf-m, 13.0 ft-lb)
BR-00021
(1)
3) Position the disc in straight position and route the brake hose through the hole in the bracket on the wheel apron side. CAUTION: Do not twist the brake hose. 4) Temporarily tighten the flare nut which connects brake pipe and hose. 5) Secure the brake hose to wheel apron bracket with clamp. 6) Tighten the flare nut to the specified torque. Tightening torque (brake pipe flare nut): 15 Nm (1.5 kgf-m, 10.8 ft-lb) 7) Bleed air from brake system.
BR-00348
(1) Brake hose
4) Tighten the flare nut to the specified torque. Tightening torque (brake pipe flare nut): 15 Nm (1.5 kgf-m, 10.8 ft-lb) 5) Bleed air from the brake system.
2. REAR BRAKE HOSE

1) Route the brake hose through the hole of bracket, and lightly tighten the flare nut to connect brake pipe. 2) Insert the clamp to secure brake hose.
C: INSPECTION
Make sure there are no cracks, breakage or damage on hoses. Check the joint for fluid leakage. If any cracks, breakage, damage or fluid leakage is found, repair or replace the hose.
(1)
(2)
(3) BR-00350
(1) Brake pipe (2) Brake hose (3) Brake hose clamp
BR-35
Brake Pipe
BRAKE
13.Brake Pipe
A: REMOVAL
NOTE: The airbag system wiring harness is routed near the center brake pipe. CAUTION: All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage the airbag system wiring harness when servicing the center brake pipe. When removing the brake pipe, do not bend.
B: INSTALLATION
NOTE: The airbag system wiring harness is routed near the center brake pipe. CAUTION: All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage the airbag system wiring harness when servicing the center brake pipe. When installing the brake pipe, do not bend. After installing the brake pipe and hose, perform air bleed. After installing the brake hoses, make sure that they do not contact the tires or suspension assembly, etc. Brake pipe tightening torque: <Ref. to BR-7, FRONT BRAKE PIPES AND HOSES, COMPONENT, General Description.> <Ref. to BR-8, CENTER AND REAR BRAKE PIPES AND HOSES, COMPONENT, General Description.>
C: INSPECTION
Make sure there are no cracks, breakage or damage on hoses. Check the joint for fluid leakage. If any cracks, breakage, damage or fluid leakage is found, repair or replace the pipes. NOTE: Use a mirror when inspecting back sides and other locations which are hard to see.
BR-36
Brake Pedal
BRAKE
14.Brake Pedal
A: REMOVAL
1. MT MODEL
1) Remove the steering shaft. 2) Disconnect the connector (stop light switch etc.) from the pedal bracket. 3) Remove the clevis pin which secures the lever and push rod. 4) Remove the nut which secures the clutch master cylinder. 5) Remove the bolt and nut which secures the pedal bracket.
2. AT MODEL
1) Remove the steering shaft. 2) Disconnect the connector (stop light switch etc.) from the pedal bracket. 3) Remove the clevis pin which secures the lever and push rod. 4) Remove the bolt and nut which secures the pedal bracket.
(1) BR-00128 (2)
(3) BR-00351
(1) Clevis pin (2) Snap pin (3) Operating rod
B: INSTALLATION
1) Install in the reverse order of removal. CAUTION: Always use a new clevis pin. 2) Check the brake pedal after installation. <Ref. to BR-38, INSPECTION, Brake Pedal.>
BR-37
Brake Pedal
BRAKE
C: INSPECTION
1) Move the brake pedal pads in a horizontal direction with a force of approx. 10 N (1 kgf, 2 lb), and check that the pedal deflection is in the range of specifications. CAUTION: If excessive deflection is noted, replace with a new bushing. Deflection of brake pedal: Limit 5.0 mm (0.197 in) or less
(1)
BR-00105
(1) Brake pedal
2) Check the position of the pedal pad. Pedal height L: 150 160 mm (5.91 6.30 in) Brake pedal free play A: 0.5 2 mm (0.02 0.08 in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lb).]
(1)
(3)
(4) A (2)
L BR-00106
(1) (2) (3) (4)
Stop light switch Mat Toe board Brake booster operating rod
3) If it is not within the specification, adjust it by adjusting the brake booster operating rod length.
BR-38
Stop Light Switch

BRAKE
15.Stop Light Switch

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Disconnect the stop light switch connector. 3) Loosen the nuts, unscrew the stop light switch, and remove stop light switch.
C: INSPECTION
1. CHECK SPECIFIED POSITION
1) If the stop light switch does not operate properly (or if it is not secured at the specified position), replace with a new part. Specified position L: 2 mm (0.079 in)
(1)
BR-00107
(1) Stop light switch
BR-00109
B: INSTALLATION
1) Install the stop light switch onto the bracket with screws and position it with the nut. 2) Adjust the stop light switch position, and then tighten the nut. <Ref. to BR-40, ADJUSTMENT, Stop Light Switch.> Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
2) Measure the clearance between the threaded end of the stop light switch and the stopper. CAUTION: Be careful not to rotate the stop light switch. Stop light switch clearance A: 0.3 mm (0.012 in)
(1)
(2) (3) T BR-00110
BR-00108
(1) Stop light switch (2) Stopper (3) Brake pedal
3) If it is not within the specification, adjust it by adjusting the position of the stop light switch. CAUTION: Be careful not to rotate the stop light switch.
BR-39
Stop Light Switch

BRAKE
2. CHECK RESISTANCE
1) If the stop light switch does not operate properly, replace with a new part. 2) Measure the resistance of stop light switch terminals.
2 1 4 3
BR-00643
Pedal Released Depressed
Terminal No. 1 and 4 2 and 3 1 and 4 2 and 3
Standard value Less than 1 : 1 M: or more 1 M: or more Less than 1 :
D: ADJUSTMENT
Loosen the lock nut, and adjust the stop light switch position until the clearance between the threaded end of the stop light switch and stopper (A) becomes 0.3 mm (0.012 in). Then, tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
(1) (2) (3) A
(4) (5) BR-00111
(1) (2) (3) (4) (5)
Stop light switch Lock nut A Lock nut B Stopper Brake pedal
NOTE: Tighten lock nut B until the threaded end of switch contacts the stopper. Hold the switch so that it does not rotate, and loosen the lock nut B approx. 60. The clearance (A) will become 0.3 mm (0.012 in).
BR-40

BRAKE

A: INSPECTION
Trouble and possible cause 1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Corrective action Correct or replace. (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose) Bleed air. Replace, grind or clean. Correct or replace. Correct the cause of fluid leakage, and clean or replace. Repair or replace the rotor. Repair by grinding, or replace. Correct or replace. Adjust the air pressure. Adjust alignment. Tighten to the specified torque. Replace. Replace the cylinder, brake pipe or hose. Check, adjust or replace the rear brake and cable system. Bleed air. Adjust. Correct or replace. (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose) Correct or replace. Adjust play. Clean or replace the cylinder. Replace. Repair or adjust. Replace the spring. Correct or replace. Replace. Replace the pad. Replace the pad. Tighten to the specified torque. Tighten to the specified torque. Clean the rotor, or clean and replace brake assembly. Replace the pad. Correct or replace the pad. Retighten or replace. Replace the pad or the support.
2. Unstable or uneven braking
(2) Entry of air into the hydraulic mechanism (3) Wear, deteriorated surface material, water or fluid on lining (4) Improper operation of master cylinder, disc caliper, brake booster or check valve (1) Fluid on lining or rotor (2) Rotor defective (3) Improper lining contact, deteriorated surface, deteriorated or worn lining material (4) Deformed back plate (5) Overinflation of tires (6) Defective wheel alignment (7) Loose back plate or support installation bolt (8) Faulty wheel bearing (9) Defective hydraulic system (10) Unstable performance of the parking brake
3. Excessive pedal stroke
(1) Entry of air into the hydraulic mechanism (2) Excessive play in the master cylinder push rod (3) Fluid leakage from the hydraulic mechanism
4. Brake dragging or improper brake return
5. Brake noise (1) (creaking sound)
(4) Improper lining contact or worn lining (1) Insufficient pedal play (2) Improper master cylinder return (3) Clogged hydraulic system (4) Improper return or adjustment of parking brake (5) Weakened spring tension or breakage of shoe return spring (6) Improper disc caliper operation (7) Faulty wheel bearing (1) Hardened or deteriorated brake pad (2) Worn brake pad (3) Loose back plate or support installation bolt (4) Loose wheel bearing (5) Dirty rotor (1) Worn brake pad (2) Improperly installed pad (3) Loose or bent rotor Excessively worn pad or support
6. Brake noise (2) (hissing sound) 7. Brake noise (3) (click sound)
BR-41

BRAKE
BR-42
General Description
PARKING BRAKE
A: SPECIFICATION
Type Effective drum diameter Lining dimensions (Length Width Thickness) Clearance adjustment Lever stroke mm (in) mm (in) Mechanical, drum in disc rear brakes 170 (6.69) 163.1 30.0 3.2 (6.421 1.181 0.126) Manual adjustment 5 6/200 (20.4, 45)
notches/N (kgf, lb)
B: COMPONENT
1. PARKING BRAKE (REAR DISC BRAKE)
(1) (17)
(2) (3) (4) (8) (7)
(6)
(9)
(11) (13) (5) (12) (15) (14) (16) PB-00048 (10)
(1) (2) (3) (4) (5) (6)
Back plate Retainer Spring washer Lever Parking brake shoe (Primary) Parking brake shoe (Secondary)
(7) (8) (9) (10) (11) (12)
Strut spring Strut Shoe guide plate Primary return spring Secondary return spring Adjusting spring
(13) (14) (15) (16) (17)
Adjuster Shoe hold-down cup Shoe hold-down spring Shoe hold-down pin Adjusting hole cover
PB-2
General Description
PARKING BRAKE
2. PARKING BRAKE CABLE

(8)
(7)
T2
(8) T2 T1 T1 (3) (6) (5)
(1)
T1 T1 (2) T1 (4) T1
T1
(9)
PB-00113
(1) (2) (3) (4) (5)
Parking brake lever Parking brake switch Adjusting nut (Self-locking nut) Equalizer Bracket
(6) (7) (8) (9)
Clamp Parking brake cable RH Clamp Parking brake cable LH
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise. Make sure grease does not come into contact with the parking shoes.
PB-3
Parking Brake Lever

PARKING BRAKE
2. Parking Brake Lever

A: REMOVAL
1) Set the wheel stoppers to tires. 2) Remove the console box. 3) Disconnect the parking brake switch connector. 4) Remove the parking cable adjusting nut (selflocking nut). 5) Remove the parking brake lever.
PB-00053
B: INSTALLATION
1) Install in the reverse order of removal. Tightening torque: Parking brake lever 18 Nm (1.8 kgf-m, 13.0 ft-lb) 2) Install a new adjusting nut (self-locking nut). 3) Be sure to adjust the lever stroke. <Ref. to PB-4, ADJUSTMENT, Parking Brake Lever.>
C: INSPECTION
1) Operate the parking brake lever 3 to 4 times and fully return the lever. 2) While slowly pulling the parking brake lever upward, count the notches. Lever stroke: 5 to 6 notches when pulled with a force of 200 N (20.4 kgf, 45 lb) If it is not within the specified value, adjust the parking brake. <Ref. to PB-8, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
D: ADJUSTMENT
Adjust the parking lever stroke. <Ref. to PB-8, LEVER STROKE, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
PB-4
Parking Brake Cable

PARKING BRAKE
3. Parking Brake Cable

A: REMOVAL
1) Remove the rear seat cushion. 2) Remove the console box. 3) Remove the parking cable adjusting nut (selflocking nut). 4) Remove the parking brake lever. <Ref. to PB-4, REMOVAL, Parking Brake Lever.> 5) Roll up the floor mat and remove the clamps.
B: INSTALLATION
1) Install in the reverse order of removal. NOTE: Be sure to pass the cable through the tunnel in the cable guide. 2) Be sure to adjust the lever stroke. <Ref. to PB-4, ADJUSTMENT, Parking Brake Lever.>
C: INSPECTION
Check and replace the removed cable if damaged, rusty or faulty. 1) Check the cable for smooth operation. 2) Check the inner cable for damage and rust. 3) Check the outer cable for damage, bends and cracks. 4) Check the boot for damage, cracks, and corrosion.
PB-00078
6) Remove the inner cable end from equalizer.
PB-00008
(1) Equalizer (2) Inner cable end
7) Lift up the vehicle, and then remove the rear wheels. 8) Remove the parking brake cable from rear brake. <Ref. to PB-6, REMOVAL, Parking Brake Assembly (Rear Disc Brake).> 9) Remove the clamp from the rear brake. 10) Remove the cable clamp from the rear arm bracket. 11) Remove the cable clamp from rear floor.
PB-00026
12) Remove the cable assembly.
PB-5
Parking Brake Assembly (Rear Disc Brake)

PARKING BRAKE
4. Parking Brake Assembly (Rear Disc Brake)

A: REMOVAL
1) Release the parking brake. 2) Remove the two mounting bolts and remove the brake caliper assembly.
(2) If disc rotor is seized on the hub, drive the disc rotor out by pushing two 8 mm bolts in holes B on the rotor.
B A BR-00036
BR-00346
5) Remove the shoe return spring from the parking brake assembly. 6) Remove the front shoe hold down spring and pin.
3) Suspend the brake caliper assembly so that the hose is not stretched. 4) Remove the disc rotor. NOTE: If the disc rotor is difficult to remove, try the following two methods in order. (1) Turn the adjusting screw using a flat tip screwdriver until the brake shoe moves adequately away from the disc rotor.
(2) (3)
PB-00028
(1) (4) BR-00155
7) Remove the strut and strut spring. 8) Remove the adjuster assembly from the parking brake assembly. 9) Remove the brake shoe. 10) Remove the rear shoe hold down spring and pin with pliers. 11) Remove the parking brake cable from lever.
(1) (2) (3) (4)
Adjuster Adjusting hole cover (rubber) Flat tip screwdriver Back plate
PB-00014
(1) Parking brake cable (2) Lever
12) Using a flat tip screwdriver, raise the retainer. Remove the parking lever and washer from brake shoe.
PB-6

PARKING BRAKE
B: INSTALLATION
CAUTION: Be sure the lining surface is free from oil and grease. 1) Apply brake grease to the following locations. Brake grease: Brake Grease (Part No. 003602002) Six contact surfaces of the shoe rim and back plate gasket Contact surface of the shoe wave and the anchor pin Contact surface of the lever and strut Contact surface of the shoe wave and the adjuster assembly Contact surface of the shoe wave and the strut Contact surface of the lever and the shoe wave 2) Insert the primary side brake shoe into the anchor pin groove. 3) Secure the brake shoe with the shoe hold-down pin and cup. 4) Install the plate to the anchor pin, then install the primary return spring.
(2) (1) (3)
6) Install the strut and adjuster, then secure the secondary side brake shoe with the shoe holddown pin and cup. NOTE: Install the strut spring of both right and left wheel facing vehicle front. Install the adjuster assembly with screw section on the left side.
PB-00016
(1) LH
7) Install the secondary return spring and the adjusting spring.

(1) (2) (4) (3)
(5) (4) (5) PB-00039 (7) (8) (6) PB-00076
(1) (2) (3) (4) (5)
Primary return spring Anchor pin Plate Primary shoe Shoe hold-down pin and shoe hold-down cup
5) Install the parking brake cable to the lever.
(1) (2) (3) (4) (5) (6) (7) (8)
Lever Secondary brake shoe Strut spring Strut Return spring Adjuster Shoe hold-down cup Adjusting spring
8) Adjust the parking brake. <Ref. to PB-8, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).> 9) Drive the vehicle to break-in the parking brake lining. (1) Drive the vehicle at about 35 km/h (22 MPH). (2) With the parking brake release button pushed in, pull the parking brake lever gently. (3) Drive the vehicle for about 200 m (0.12 mile) in this condition. (4) Wait 5 to 10 minutes for the parking brake to cool down. Repeat again from step (1). (5) After breaking-in, re-adjust the parking brakes.
PB-7

PARKING BRAKE
C: INSPECTION
1) Measure the brake disc rotor inside diameter. If the disc is scored or worn, replace the brake disc rotor. Disc rotor inside diameter: Standard: 170 mm (6.69 in) Service limit: 171 mm (6.73 in) 2) Measure the lining thickness. If it exceeds the limit, replace shoe assembly. Lining thickness: Standard: 3.2 mm (0.126 in) Service limit: 1.5 mm (0.059 in) NOTE: Replace the right and left brake shoe as a set.
2. LEVER STROKE
1) Adjust the shoe clearance before adjusting lever stroke. <Ref. to PB-8, SHOE CLEARANCE, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).> 2) Remove the parking lever cover. 3) Operate the parking brake lever 3 to 4 times. 4) Turn the adjusting nut until the lever stroke is at the specified value. Lever stroke: 5 to 6 notches when pulled with a force of 200 N (20.4 kgf, 45 lb)
D: ADJUSTMENT
1. SHOE CLEARANCE
1) Return the parking brake lever fully. 2) Remove the adjusting hole cover from the back plate. 3) Turn the adjusting screw using a flat tip screwdriver until the brake shoe is in close contact with the disc rotor.
(2) (3) (1) PB-00054
(1) Adjusting nut (Self-locking nut)
5) Check there is no brake drag. 6) Install the parking lever cover.
(1) (4) PB-00032
(1) (2) (3) (4)
Adjusting screw Adjusting hole cover (rubber) Flat tip screwdriver Back plate
4) Turn back (downward) the adjusting screw 3 to 4 notches. CAUTION: Check there is no brake drag. 5) Install the adjusting hole cover to the back plate. 6) Adjust the parking lever stroke. <Ref. to PB-8, LEVER STROKE, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
PB-8

PARKING BRAKE

A: INSPECTION
Symptoms Possible cause Parking brake lever not adjusted correctly. Parking brake cable does not move. Parking brake shoe clearance is maladjusted. Return spring is faulty. Return spring is faulty. Shoe hold-down spring faulty. Corrective action Adjust. Correct or replace. Adjust. Replace. Replace. Replace.
Brake drag
Noise from brake
PB-9

PARKING BRAKE
PB-10
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
A: SPECIFICATION
Model Minimum turning radius Inner wheel Whole system Steering angle Outer wheel Steering wheel diameter Lock to lock turn Type Backlash Valve (Power steering system) Type Oil tank Specific output Relief pressure Hydraulic fluid control Hydraulic fluid RPM range Direction of rotation Hydraulic oil (Power steering system) Steering wheel Steering shaft Steering gearbox (Power steering system) Capacity mm (in) m (ft) Except for 3.0 R 3.0 R Except for 3.0 R-LTD, 2.5 GT spec. B: 5.4 (17.8) 3.0 R-LTD, 2.5 GT spec. B: 5.8 (19) Except for 3.0 R-LTD, 2.5 GT spec. B: 37.6r1.5 3.0 R-LTD, 2.5 GT spec. B: 33.8r1.5 Except for 3.0 R-LTD, 2.5 GT spec. B: 33.0r1.5 3.0 R-LTD, 2.5 GT spec. B: 30.2r1.5 375 (14.76) 3.0 R-LTD, 2.5 GT-B: 2.6, 2.5 GT: 2.8, Others: 3.2 Rack and Pinion, Integral 0 (Automatic adjusting) Rotary valve Vane pump Installed on body 8.5 (0.519) 9.6 (0.586)
Gearbox
cm3 (cu in)/rev.
Pump (Power steering system)
Non-turbo: 7,350 8,050 (75 82, 1,067 1,167) 8,300 9,000 2 kPa (kg/cm , psi) Turbo: 8,100 8,800 (85 92, 1,204 1,305) (83 90, 1,174 1,276) Engine speed sensitive 1,000 rpm: 6.15 (6.5, 5.4) 1,000 rpm: 6.5 (6.9, 5.7) 2 (USqt, Imp qt) 3,000 rpm: 5.5 (5.8, 4.8) 3,000 rpm: 5.5 (5.8, 4.8) rpm 680 9,600 Clockwise Oil tank 0.2 (0.2, 0.2) 0.7 (0.7, 0.6)
2 (US qt, Imp qt) Whole system
Free play Clearance between the steering wheel and column cover Rack shaft play in Right-turn steering the radial direction In radial direction Input shaft play In axial direction Rotation resistance
mm (in) mm (in) mm (in) mm (in) mm (in) N (kgf, lb)
17 (0.67) 3.0 (0.12) 0.12 (0.005) or less 0.26 (0.01) or less Without play Maximum allowable value: 11.3 (1.15, 2.54) or less Difference between right and left sliding resistance: 24% or less 0.4 (0.016) or less 0.9 (0.035) or less 1.0 (0.039) or less 9.22(0.94, 2.07) or less 981(10, 142) or less 29.4(3.0, 6.6) or less 294.2(30, 66.2) or less
Oil pump (Power steering system) Steering wheel effort (Power steering system)
Radial play mm (in) Axial play mm (in) Ditch deflection mm (in) Pulley Rotation resistance N (kgf, lb) Regular pressure (Unloaded) kPa (kg/cm2, psi) At standstill with engine idling on paved N (kgf, lb) road At standstill with engine stalled on paved N (kgf, lb) road Pulley shaft
Recommended power steering fluid SUBARU ATF or ATF DEXRON III
PS-2
General Description
B: COMPONENT
1. STEERING WHEEL AND COLUMN
(1)
(2)
(3) T2 (8) T1
(4)
(7)
T3
(5)
(6)
T1 PS-00948
(1) (2) (3) (4)
Bushing Steering shaft Steering roll connector Column cover
(5) (6) (7) (8)
Steering wheel Airbag module Steering wheel lower cover Paddle shift
PS-3
General Description
2. POWER ASSISTED SYSTEM

Hose and tank
(12) T3
(14)
T2 (12) (6) T4 (1) (2) (7) (13) T1 (15) (4) T3 T5 (1) (5) (3) (5) (11)
(10) (3) (8) (9) (4) (8) PS-00806 (16)
(1) (2) (3) (4) (5) (6) (7) (8)
Eye bolt Hose (H4 model) Eye bolt gasket Clip Clamp E Cap Reservoir tank Pulley
(9) (10) (11) (12) (13) (14) (15) (16)
Oil pump (H4 model) Suction hose Hose bracket Clip Clip Return hose Hose (H6 model) Oil pump (H6 model)
Tightening torque:Nm (kgf-m, ft-lb) T1: 7.5 (0.76, 5.53) T2: 10 (1.02, 7.4) T3: 13 (1.32, 9.6) T4: 18 (1.84, 13.3) T5: 40 (4.1, 29.5)
PS-4
General Description
Gearbox
(39) (20) (21) T11 (22) T8 (23) (24) (25) (26) (31) T13 (27) (28) (29) (30) T14 (38) T12 (37) (36) (35) T13 (26) (32) T8 (39) (34) (43) (41) (33) (14) (12) (13) (15) (42) T14 (22) (30) T11 (29) (28) (27) (24) (25) (1) T7 T1 T10 T6 T3 (3) T9 (8) (9) (10) (11) (2) (4) (5) (6) (7) (3) T2 T6 T5
(16) (17) (18) (19)
T4 (40)
(23) T8
(44)
PS-00849
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Feed pipe Return pipe Clamp plate Universal joint Dust seal Valve housing O-ring Oil seal Bushing Seal ring Pinion & valve ASSY Oil seal Back-up washer Ball bearing Snap ring Lock nut Adjusting screw Spring Sleeve Adapter
(21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40)
Clamp Cotter pin Castle nut Dust cover Clip Tie-rod end Clip Boot Band Tie-rod Pipe B Pipe A Steering body Oil seal Piston ring Rack Oil seal Holder O-ring Bracket
(41) (42) (43) (44)
Bushing Lock washer Back-up washer O-ring
Tightening torque:Nm (kgf-m, ft-lb) T1: 3.9 (0.4, 2.9) T2: 9 (0.9, 6.6) T3: 15 (1.5, 10.8) T4: 17 (1.7, 12.5) T5: 20 (2.0, 14.8) T6: 24 (2.4, 17.7) T7: 25 (2.5, 18.4) T8: 27 (2.75, 19.9) T9: 37 (3.8, 27.3) T10: 29 (3.0, 21.4) T11: 60 (6.1, 44.1) T12: 70 (7.1, 51.6) T13: 85 (8.7, 62.7) T14: 88 (9.0, 64.9)
PS-5
General Description
3. OIL PUMP
H4 model
T1
T5
T3
(1)
(2) T2 (3)
T3 T3 (4)
T4 PS-00988
(1) (2)
Oil pump Pulley
(3) (4)
Bracket Belt tension nut
Tightening torque:Nm (kgf-m, ft-lb) T1: 8 (0.8, 5.8) T2: 15.7 (1.6, 11.6) T3: 22 (2.2, 15.9) T4: 25 (2.5, 18.4) T5: 48.4 (4.9, 35.7)
PS-6
General Description
H6 model
T3 T2 (3)
T4 T1 (1)
(2) T3
T3
(4)
PS-00699
(1) (2)
Oil pump Pulley
(3) (4)
Bracket Belt tensioner
Tightening torque:Nm (kgf-m, ft-lb) T1: 15.7 (1.6, 11.6) T2: 25 (2.5, 18.4) T3: 33 (3.4, 24.3) T4: 37.3 (3.8, 27.5)
PS-7
General Description
C: CAUTION
Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. Use SUBARU genuine power steering fluid, grease etc. or the equivalent. Do not mix fluid, grease etc. of different grades or manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or rigid racks at the specified points. Before securing a part on a vise, place cushioning material such as wooden blocks, aluminum plate or cloth between the part and the vise.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER 925711000 DESCRIPTION PRESSURE GAUGE REMARKS Used for measuring oil pressure.
ST-925711000
926200000
STAND
Used when inspecting characteristic of gearbox assembly and disassembling it. Used together with BOSS D (34199AG000).
ST-926200000
34099AC010
ADAPTER HOSE A
Used together with PRESSURE GAUGE (925711000).
ST34099AC010
PS-8
General Description
ILLUSTRATION TOOL NUMBER 34099AC020 DESCRIPTION ADAPTER HOSE B REMARKS Used together with PRESSURE GAUGE (925711000).
ST34099AC020
926230000
SPANNER
For the lock nut when adjusting backlash of gearbox.
ST-926230000
34099PA100
SPANNER
Used when measuring the rotating resistance of gearbox assembly.
ST34099PA100
926420000
PLUG
When fluid leaks from pinion side of gearbox assembly, remove pipe B from valve housing, attach this tool and check fluid leaking points.
ST-926420000
926390001
COVER & REMOVER ASSY
Used for installing rack assembly.
ST-926390001
PS-9
General Description
ILLUSTRATION TOOL NUMBER 34099FA060 DESCRIPTION PUNCH HOLDER REMARKS Used for crimping.
ST34099FA060
34199FE000
INSTALLER & REMOVER
Used for removing and installing the rack oil seal (outer & inner).
ST34199FE000
34199AG000
BOSS D
Used when inspecting characteristic of gearbox assembly and disassembling it. Used together with STAND (926200000).
ST34199AG000
34199AG030
GUIDE
Used for installing seal ring of rack.
ST34199AG030
34199AG070
FORMER
Used for forming seal ring of pinion.
ST34199AG070
PS-10
General Description
ILLUSTRATION TOOL NUMBER 34199AG020 DESCRIPTION GUIDE REMARKS Used for installing seal ring of pinion.
ST34199AG020
34199AG050
GUIDE G (24)
Used for forming seal ring of rack. Used together with FORMER PISTON (34199AG080).
ST34199AG050
34099FA140
OIL SEAL REMOVER
Used for removing oil seal.
ST34099FA140
34199AG090
INSTALLER & REMOVER
Used for installing oil seal of valve housing. Used together with the SEAL INSTALLER. (34099FA130) Used for installing ball bearing of valve housing. Used for removing oil seal and ball bearing from valve housing.
ST34199AG090
34199AG080
FORMER PISTON
Used for forming seal ring of rack. Used together with the GUIDE G (24) (34199AG050).
ST34199AG080
PS-11
General Description
ILLUSTRATION TOOL NUMBER 34199AG010 DESCRIPTION INSTALLER REMARKS Used for pressing-fit oil seal of gearbox cylinder.
ST34199AG010
34199FE020
BASE
Used for crimping.
ST34199FE020
PS-12
Steering Wheel
2. Steering Wheel
A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Set the tire to the straight-ahead position. 3) Remove the airbag module. <Ref. to AB-14, REMOVAL, Drivers Airbag Module.> WARNING: Always refer to Airbag System before performing service on the airbag modules. <Ref. to AB-4, CAUTION, General Description.> 4) Place alignment marks on the steering wheel and steering shaft.
B: INSTALLATION
WARNING: Always refer to Airbag System before performing service on the airbag modules. <Ref. to AB-4, CAUTION, General Description.> 1) Align the center position of the roll connector. <Ref. to AB-25, ADJUSTMENT, Roll Connector.> 2) Install in the reverse order of removal. NOTE: Align the alignment marks on the steering wheel and steering shaft. Tightening torque: 39 Nm (4.0 kgf-m, 28.8 ft-lb) Column cover-to-steering wheel clearance: 2 4 mm (0.08 0.16 in) CAUTION: Insert the roll connector guide pin into the guide hole on the lower end of the steering wheel surface. Avoid damaging the pin.
(1) PS-00552
C: INSPECTION
1) Check the steering wheel for deformation. If the deformation is excessive, replace the steering wheel. 2) Check the splines on the steering wheel for damage. If the damage is excessive, replace the steering wheel.
(1) Alignment mark
5) Remove the steering wheel nut, and then draw out the steering wheel from shaft using steering puller.
PS-13
Universal Joint
3. Universal Joint
A: REMOVAL
1) Remove the steering wheel. <Ref. to PS-13, REMOVAL, Steering Wheel.> 2) Place alignment marks on universal joint. 3) Remove the universal joint bolt, and then remove the universal joint.
B: INSTALLATION
1) Align the cutout portion at serrated section of the column shaft and yoke, then install the universal joint into column shaft.
(1) (2) (3)
(1) (4)
PS-00443
(5) PS-00032
(1) (2) (3) (4) (5)
Cutout portion Yoke Column shaft Column shaft side Gearbox side
2) Install the universal joint to the serrations of gearbox assembly by matching alignment marks. 3) Tighten the bolts. Tightening torque: 24 Nm (2.4 kgf-m, 17.7 ft-lb) CAUTION: Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation. 4) Align the center position of the roll connector. <Ref. to AB-25, ADJUSTMENT, Roll Connector.> 5) Install the steering wheel. <Ref. to PS-13, INSTALLATION, Steering Wheel.>
PS-14
Universal Joint
C: INSPECTION
Check for wear, damage or any other faults. Replace as necessary. Service limit: Universal joint play: 0 mm (0 in) Maximum swing torque: 0.3 N (0.03 kgf, 0.07 lb)
Service limit: Maximum load: 7.3 N (0.74 kgf, 1.64 lb) or less
(1)
(1) PS-00036
(1) Yoke (Steering column side)
(2) PS-00033
(1)
(1) Swing torque (2) Play
Measure the swing torque of universal joint. Service limit: Maximum load: 3.8 N (0.39 kgf, 0.86 lb) or less
(1) PS-00037
(1) Yoke (Steering column side)
PS-00034
(1) Yoke (Gearbox side)
(1)
PS-00035
(1) Yoke (Gearbox side)
PS-15
Tilt Steering Column

4. Tilt Steering Column

A: REMOVAL
(1)
(2)
PS-00768
(1)
Tilt steering column
(2)
Universal joint
1) Remove the steering wheel. <Ref. to PS-13, REMOVAL, Steering Wheel.> 2) Remove the universal joint. <Ref. to PS-14, REMOVAL, Universal Joint.> 3) Remove the instrument panel lower cover under. 4) Remove the instrument panel lower cover upper. 5) Remove all connectors from the steering column. 6) Remove the two bolts under instrument panel securing the steering column.
PS-00798
PS-16
Tilt Steering Column

7) Pull out the steering shaft assembly from the hole on toe board. CAUTION: Be sure to remove the universal joint before removing steering shaft assembly installing bolts when removing steering shaft assembly or when lowering it for servicing other parts. Do not loosen the tilt lever when the steering column is not secured to the vehicle.
D: ASSEMBLY
Insert the combination switch to the upper column shaft, and install the upper column cover. Then route the ignition key harness and combination switch harness between the column cover mounting bosses. Tightening torque: 1.2 Nm (0.12 kgf-m, 0.9 ft-lb) CAUTION: Do not overtorque the screw.
B: INSTALLATION
1) Install the grommet to the toe board.
E: INSPECTION
1. BASIC INSPECTION
Measure the overall length of steering column. If not within specification, replace it. Standard: Overall length L Tilt & telescopic column (measure the minimum length) Except for OUTBACK model 818.6+1.5 mm 1.5 mm (32.23 +0.059 in 0.059 in) OUTBACK model 810.4+1.5 mm 1.5 mm (31.89 +0.059 in 0.059 in)
PS-00041
2) Insert the end of the steering shaft into the toe board grommet. 3) With the tilt lever secured, tighten the steering shaft mounting bolts under instrument panel. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 4) Connect all the connectors under the instrument panel. 5) Connect the airbag system connector at the harness spool. NOTE: Make sure to apply double lock. 6) Install the instrument panel lower cover with tilt lever held in the lowered position. 7) Install the universal joint. <Ref. to PS-14, INSTALLATION, Universal Joint.> 8) Align the center position of the roll connector. <Ref. to AB-25, ADJUSTMENT, Roll Connector.> 9) Install the steering wheel. <Ref. to PS-13, INSTALLATION, Steering Wheel.> CAUTION: Insert the roll connector guide pin into the guide hole on lower end of steering wheel surface to prevent damage.
PS-00491
2. INSPECTION OF AIRBAG SYSTEM

Refer to Airbag System for airbag inspection procedures. <Ref. to AB-14, INSPECTION, Drivers Airbag Module.>
C: DISASSEMBLY
Remove the two screws securing the upper steering column covers, and the two screws securing the combination switch, and then remove related parts.
PS-17
Steering Gearbox
5. Steering Gearbox
A: REMOVAL
1) Set the vehicle on a lift. 2) Disconnect the ground cable from the battery. 3) Loosen the front wheel nuts. 4) Lift up the vehicle, and remove the front wheels. 5) Remove the under cover. <Ref. to EI-26, REMOVAL, Front Under Cover.> 6) Remove the front exhaust pipe assembly. (Nonturbo model) <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.> WARNING: Be careful not to burn yourself because the exhaust pipe is hot. 7) After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.
Small type
(2) (1)
(1) FS-00105
9) Remove the one pipe joint at the center of the gearbox, and connect the vinyl hose to the pipe and the joint. Discharge the fluid by turning the steering wheel fully clockwise and counterclockwise. Discharge the fluid similarly from other pipes.
(1)
(1) (2) (3) PS-00043 (2) PS-00553
(1) Castle nut (2) Tie-rod end (3) Knuckle arm
(1) Pipe A (2) Pipe B
8) Remove the front crossmember support plate, jack-up plate and front stabilizer. <Ref. to FS-15, REMOVAL, Front Stabilizer.> Large type
10) Remove the universal joint. <Ref. to PS-14, REMOVAL, Universal Joint.>
(1) PS-00445
(1) Front crossmember support plate
PS-18
Steering Gearbox
11) Disconnect the pipe C from pressure hose first, then disconnect pipe D from the return hose.
13) Remove the bolts which secure the gearbox bracket, and remove the bracket and gearbox.
(1)
(4) (3) PS-00555 (2)
(1) Bracket
B: INSTALLATION
(1)
1) Insert the gearbox into crossmember, being careful not to damage gearbox boot. 2) Install the gearbox and bracket. Temporarily tighten the bolts.
PS-00538
(1)
(1) (2) (3) (4)
Pipe C Pipe D Pressure hose Return hose

PS-00555
12) Remove the clamp bolts securing the gearbox to the crossmember, and remove the clamp.
(1) Bracket
3) Insert bolts through the clamp to temporarily tighten the gearbox to the crossmember bracket.
(1) PS-00554
(1) Clamp
(1) PS-00554
(1) Clamp
4) Tighten the bolts temporarily holding the gearbox clamp and bracket together to the specified torque. Tightening torque: 60 Nm (6.1 kgf-m, 44.1 ft-lb)
PS-19
Steering Gearbox
5) Connect pipe D to the return hose, then connect pipe C to the pressure hose. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
8) After tightening the castle nut to the specified tightening torque, tighten it further within 60 until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.
(A)
(B)
(4) (3) (2)
(C)
DS-00042
(1)
(A) Cotter pin (B) Castle nut (C) Tie-rod end
PS-00538
(1) (2) (3) (4)
9) Install the front stabilizer. <Ref. to FS-15, INSTALLATION, Front Stabilizer.> 10) Install the front crossmember support plate and jack-up plate. 11) Install the front exhaust pipe assembly. (Nonturbo model) <Ref. to EX(H4SO)-5, INSTALLATION, Front Exhaust Pipe.> 12) Install the under cover. <Ref. to EI-26, INSTALLATION, Front Under Cover.> 13) Install the front wheels. 14) Tighten the wheel nuts to the specified torque. Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft-lb) 15) Lower the vehicle. 16) Remove the steering wheel. <Ref. to PS-13, REMOVAL, Steering Wheel.> 17) Align the center position of the roll connector. <Ref. to AB-25, ADJUSTMENT, Roll Connector.> 18) Install the steering wheel. <Ref. to PS-13, INSTALLATION, Steering Wheel.> 19) Connect the ground cable to battery. 20) Pour fluid into the oil tank, and bleed air. <Ref. to PS-53, Power Steering Fluid.> 21) Check for fluid leaks. 22) Check the fluid level in oil tank.
6) Install the universal joint. <Ref. to PS-14, INSTALLATION, Universal Joint.> 7) Connect the tie-rod end and knuckle arm, and tighten with castle nut. Castle nut tightening torque: 27 Nm (2.75 kgf-m, 19.9 ft-lb) CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer.
PS-20
Steering Gearbox
23) After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end. Tightening torque: 85 Nm (8.7 kgf-m, 62.7 ft-lb) NOTE: When adjusting toe-in, hold the boot as shown to prevent it from being rotated or twisted. If it becomes twisted, straighten it.
4) Remove the small clip from the boot using pliers, and then move the boot to tie-rod end side.
(1)
PS-00053
(1) Clip
5) Using a flat tip screwdriver, remove the band from boot.

PS-00051
C: DISASSEMBLY
1. RACK HOUSING ASSEMBLY
1) Disconnect the four pipes from gearbox. NOTE: Remove the pipes C and D, which are fixed to clamp plate, as a unit. 2) Secure the gearbox removed from vehicle in a vise using ST. ST1 926200000 STAND ST2 34199AG000 BOSS D CAUTION: Secure the gearbox in a vise using ST as shown in the figure. Do not secure the gearbox without this ST.
(1)
NOTE: Replace the boot if there is damage, cracks or deterioration.
(1)
PS-00509
(1) Band
6) Using the ST, loosen the lock nut. ST 926230000 SPANNER

ST
ST1 ST2 PS-00492
(1) PS-00494
(1) Clamp
(1) Lock nut
3) Remove the tie-rod end and lock nut from gearbox.
PS-21
Steering Gearbox
7) Tighten the adjusting screw until it can no longer be tightened.

(1)
12) Using a drill, release the crimping of holder. CAUTION: Make a hole of 2 mm (0.08 in) depth using a drill with 3 mm (0.12 in) diameter.
PS-00495
(1) Adjusting screw

PS-00516
8) Remove the tie-rod using ST. ST 926230000 SPANNER 9) Loosen the adjusting screw, and remove the spring and sleeve. 10) Remove the two bolts securing valve assembly.
13) Remove the holder. 14) Attach the ST to the pinion housing side of the rack, and push out the rack together with the outer side oil seal. ST 34199FE000 INSTALLER & REMOVER NOTE: Block the pipe connection of steering body to prevent fluid from flowing out.
PS-00116
11) Carefully draw out the input shaft and remove the valve assembly.
PS-00117 PS-00064
(1) Rack piston (2) Outer side oil seal
PS-22
Steering Gearbox
15) Insert the ST from pinion housing side and remove the oil seal using a press. ST 34099FA140 OIL SEAL REMOVER
(1)
2. CONTROL VALVE
1) Disconnect the pipes A and B from gearbox. 2) Secure the gearbox removed from vehicle in a vise using ST. ST1 926200000 STAND ST2 34199AG000 BOSS D CAUTION: Secure the gearbox in a vise using ST as shown in the figure. Do not secure the gearbox without this ST.
(1)
ST
(2) ST1 ST2 PS-00492
(1) Clamp
PS-00138
3) Using the ST, loosen the lock nut. ST 926230000 SPANNER

ST
(1) Press (2) Oil seal
16) Using a press, remove the bushing of gearbox installation portion.
(1) PS-00494
(1) Lock nut
PS-00517
4) Tighten the adjusting screw until it can no longer be tightened.

(1)
PS-00495
(1) Adjusting screw
5) Loosen the adjusting screw, and remove the spring and sleeve.
PS-23
Steering Gearbox
6) Remove the two bolts securing valve assembly.
10) Using the ST and a press, remove the bushing and oil seal from the valve housing. ST 34199AG090 INSTALLER & REMOVER CAUTION: Do not apply a force to the end surface of valve housing. Do not reuse the oil seal after removal.
PS-00116
ST (1)
7) Carefully draw out the input shaft and remove the valve assembly.
(2)
PS-00855
(1) Oil seal (2) Bushing
11) Using a snap ring pliers, remove the snap ring, valve, oil seal and back-up washer.
PS-00143
8) Put a vinyl tape around the spline portion, and slide the dust cover to remove.
(1)
CAUTION: Be careful not to scratch the pinion and valve assembly.

(4) (3) (2) (1)
PS-00144
PS-00518
(1) Dust cover
9) Using a press, remove the pinion & valve assembly from valve housing.
(1) (2) (3) (4)
Snap ring Valve Oil seal Back-up ring
(1) (2)
(3)
PS-00149
(1) Pinion & valve ASSY (2) Valve housing (3) Cloth
PS-24
Steering Gearbox
D: ASSEMBLY
1. RACK HOUSING ASSEMBLY
1) Using a press, install the bushing to gearbox installation portion.
5) Attach the ST to the teeth of rack assembly, and insert the oil seal into the rack. ST 926390001 COVER & REMOVER
ST
(1)
PS-00161
PS-00519
(1) Rack ASSY
2) Insert the ST to rack. ST 34199AG030 GUIDE
6) Remove the ST from the rack assembly. 7) Install the back-up washer from the gear side of rack.
(1) (2)
ST PS-00520
(1) Seal ring (2) Rack (1) Oil seal (2) Back-up washer (3) Rack
PS-00077
3) Install the seal ring to piston portion of rack. 4) Using the ST, form the seal ring properly. ST1 34199AG080 FORMER PISTON ST2 34199AG050 GUIDE G (24)
(1) (2)
8) Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty. 9) Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Then insert the rack into steering body from cylinder side. 10) Temporarily tighten a new holder to the gearbox cylinder.
ST2
ST1 PS-00559
(1) Seal ring (2) Rack
PS-25
Steering Gearbox
11) Put a mark at the specified position measured from the end surface of ST, as shown in the figure. Specified position: Except for 2.5 GT-B and 3.0 R-LTD: 13.5 mm (0.53 in) 2.5 GT-B and 3.0 R-LTD: 18.9 mm (0.74 in) ST 34199FE000 INSTALLER & REMOVER
(2)
(1)
16) Make the ST and the pipe through the rack, and then press-fit the outer side oil seal using a press. ST 34199AG010 INSTALLER
PS-00852
(1) Pipe (2) Outer side oil seal
PS-00851
(1) 13.5 mm (0.53 in) or 18.9 mm (0.74 in) (2) Put a mark.
17) Secure the gearbox in a vise using ST. ST1 926200000 STAND ST2 34199AG000 BOSS D
(1)
12) Set the ST to the end of rack. ST 34199FE000 INSTALLER & REMOVER 13) Using a press, press-fit until the mark on ST is aligned to the end surface of holder.
ST1 ST ST2 PS-00492
(1) Clamp
(1) (2)
18) Tighten a new holder. Tightening torque: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
PS-00522
(1) Mark (2) Holder
14) Remove the ST and holder. 15) Insert the outer side oil seal into the rack using the same procedure as steps 5) and 6). ST 926390001 COVER & REMOVER
PS-26
Steering Gearbox
19) Using the ST, crimp so that the diameter of punch hole is 2 2.5 mm (0.08 0.10 in) and is aligned to the position of 2 mm (0.08 in) from gearbox cylinder end surface. ST1 34099FA060 PUNCH HOLDER ST2 34199FE020 BASE
ST1
21) Apply the genuine grease to the pinion gear and bearing of valve assembly.
(A) PS-00165
22) Install a new gasket on valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.
(B)
ST1
ST2 PS-00859
PS-00117
23) Tighten the bolts alternately to secure the valve assembly. Tightening torque: 20 Nm (2.0 kgf-m, 14.8 ft-lb) CAUTION: Be sure to alternately tighten the bolts. 24) Temporarily install the tie-rod to rack end, and then operate the rack from lock to lock for two or three times to make it fit in. CAUTION: Operating the rack from lock to lock without installing tie-rods may damage the oil seal. Always install the left and right tie-rods. 25) Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread. Liquid gasket: THREE BOND 1141
(A) Holder (B) 2 mm (0.08 in)
20) Put a vinyl tape around the spline portion and apply genuine grease to the dust cover and install to valve assembly. CAUTION: Be sure to install the dust cover to groove of shaft.
(1)
(2)
PS-00534
(1) Dust cover (2) Groove
PS-27
Steering Gearbox
26) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body. Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.
33) Install the tie-rod and new lock washer into rack. Tightening torque: 90 Nm (9.1 kgf-m, 65.8 ft-lb)
(2)
(3) (2) (1) PS-00167
(1) PS-00439
(1) Sleeve (2) Spring (3) Adjusting screw
(1) Lock washer (2) Approx. 40 mm (1.57 in)
34) Bend the lock washer and crimp it. CAUTION: Be careful not to scratch the rack when crimping lock washer.
27) Tighten the adjusting screw to the specified torque, then loosen it. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 28) Tighten the adjusting screw to the specified torque, then loosen it 20. Tightening torque: 3.9 Nm (0.4 kgf-m, 2.9 ft-lb) 29) Remove the tie-rod. 30) Adjust the adjustment screw until the rotational resistance of gearbox is within specifications. <Ref. to PS-35, TURNING RESISTANCE OF GEARBOX, INSPECTION, Steering Gearbox.> 31) Apply liquid gasket to lock nut and install it into adjusting screw. While holding the adjusting screw with wrench, tighten the lock nut using ST. Liquid gasket: THREE BOND 1141 ST 926230000 SPANNER Tightening torque (lock nut): 25 Nm (2.5 kgf-m, 18.4 ft-lb) NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut. 32) Extend the rack approx. 40 mm (1.57 in) from steering body.
PS-00093
(1) Lock washer
PS-28
Steering Gearbox
35) Apply a coat of grease to the tie-rod groove, and then install the boot to the housing. CAUTION: Right side boot has groove for identification, be sure to install the right and left of boot.
(1)
36) Install a new boot band. Using band clamp pliers, crimp it so that the clearance of crimping portion becomes 2 mm (0.079 in) or less.
(B)
(A) (2) PS-00524
(1) Right side boot (2) Groove for identification
NOTE: Make sure that the boot is installed without unusual inflation or deflation.
PS-00499
(A) Boot band (B) 2 mm (0.079 in) or less
37) Fix the boot end with small clip.
PS-00194
(1)
PS-00053
(1) Clip
38) After installing, check that the boot end is installed to the groove of the tie-rod.
PS-29
Steering Gearbox
39) If the tie-rod end has been removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure. Installed tie-rod length L: 31 mm (1.22 in)
(2) Connect the pipes C and D to gearbox. Tightening torque: Pipe C: 37 Nm (3.8 kgf-m, 27.3 ft-lb) Pipe D: 29 Nm (3.0 kgf-m, 21.4 ft-lb)
(2) L
(1)
PS-00525
PS-00097
40) Inspect the gearbox as follows. Holding the A tie-rod end, repeat movement from lock to lock two or three times as quickly as possible. Holding the B tie-rod end, turn a few times as slowly as possible. Finally, make sure that the boot is installed in the specified position without inflating.
(1) Pipe C (2) Pipe D
2. CONTROL VALVE ASSEMBLY

Specified steering grease: VALIANT GREASE M2 (Part No. 003608001) 1) Clean all parts and tools before reassembling. 2) Apply a coat of specified power steering fluid to the inner wall of valve housing.
PS-00098
(1)
PS-00169
41) Remove the gearbox from ST. ST1 926200000 STAND ST2 34199AG000 BOSS D 42) Install the four pipes on gearbox. (1) Connect the pipes A and B to the four pipe joints of gearbox. Tightening torque: Refer to the component parts. <Ref. to PS-4, POWER ASSISTED SYSTEM, COMPONENT, General Description.>
(1) Apply fluid.
3) Apply grease to the oil seal. 4) Verify the direction of oil seal. 5) Using the ST and a press, install the oil seal and the bushing in valve housing. ST 34199AG090 INSTALLER & REMOVER
ST
(1) (2)
PS-00856
(1) Bushing (2) Oil seal
PS-30
Steering Gearbox
6) Apply vinyl tape to the groove of pinion. 7) Install the back-up ring and oil seal to pinion, and then remove the vinyl tape.
11) Install the valve to pinion, and install the snap ring.
(2)
(3) (1)
(2)
(1) PS-00528
PS-00531
(1) Oil seal (2) Vinyl tape (3) Back-up ring
(1) Snap ring (2) Valve
12) Attach the pinion and valve assembly into the valve housing.
8) Attach the ST to pinion, and install the seal ring. ST 34199AG020 GUIDE
ST
(2)
(1) (1) PS-00532
PS-00529
(1) Valve housing (2) Pinion & valve ASSY
(1) Seal ring
9) Remove the ST GUIDE, and form the seal ring properly using ST FORMER. ST 34199AG070 FORMER
13) Using a press, push the outer race of bearing and press-fit the pinion & valve assembly into housing.
(1) ST (2) (1) (3)
PS-00533 PS-00530
(1) Seal ring
10) Put vinyl tape around pinion shaft spline to protect oil seal from damage.
(1) Pinion & valve ASSY (2) Bearing (3) Housing
14) Apply the specified grease to dust cover.
PS-31
Steering Gearbox
15) Install the dust cover on valve assembly. CAUTION: Be sure to install the dust cover to groove of shaft.
(1)
18) Insert the valve assembly into place while facing the rack teeth toward pinion.
(2) PS-00143
PS-00534
19) Tighten the bolts alternately to secure the valve assembly. Tightening torque: 20 Nm (2.0 kgf-m, 14.8 ft-lb) CAUTION: Be sure to alternately tighten the bolts. 20) Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread. Liquid gasket: THREE BOND 1141 (Part No. 004403006) 21) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body. Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.
(1) Dust cover (2) Groove
16) Apply the genuine grease to the pinion gear and bearing of valve assembly.
PS-00165
17) Install new O-ring to valve assembly.
(3) (2) (1) (1) PS-00167
PS-00535
(1) O-ring
(1) Sleeve (2) Spring (3) Adjusting screw
22) Tighten the adjusting screw to the specified torque, then loosen it. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 23) Tighten the adjusting screw to the specified torque, then loosen it 20. Tightening torque: 3.9 Nm (0.4 kgf-m, 2.9 ft-lb)
PS-32
Steering Gearbox
24) Adjust the adjustment screw until the rotational resistance of gearbox is within specifications. <Ref. to PS-35, TURNING RESISTANCE OF GEARBOX, INSPECTION, Steering Gearbox.> 25) Apply liquid gasket to lock nut and install it into adjusting screw. While holding the adjusting screw with wrench, tighten the lock nut using ST. Liquid gasket: THREE BOND 1141 ST 926230000 SPANNER Tightening torque (lock nut): 25 Nm (2.5 kgf-m, 18.4 ft-lb) NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut. 26) Remove the gearbox from ST. ST1 926200000 STAND ST2 34199AG000 BOSS D 27) Install the four pipes on gearbox. (1) Connect the pipes A and B to gearbox. Tightening torque: Refer to the component parts. <Ref. to PS-4, POWER ASSISTED SYSTEM, COMPONENT, General Description.> (2) Connect the pipes C and D to gearbox. Tightening torque: Pipe C: 37 Nm (3.8 kgf-m, 27.3 ft-lb) Pipe D: 29 Nm (3.0 kgf-m, 21.4 ft-lb)
(2)
(1)
PS-00525
(1) Pipe C (2) Pipe D
PS-33
Steering Gearbox
E: INSPECTION
1. BASIC INSPECTION
1) Clean all the disassembled parts, and check for wear, damage or any other faults, then repair or replace as necessary. 2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.
No. 1 2 Parts Input shaft Dust seal Inspection (1) Bent input shaft (2) Damage on serration (1) Crack or damage (2) Wear Corrective action If the bend or damage is excessive, replace the entire gearbox. If the outer wall slips, the lip is worn out or damage is found, replace it with a new part. (1) Adjust the backlash properly. By measuring the turning torque of the gearbox and sliding resistance of rack, check if the rack & pinion engage uniformly and smoothly with each other. (Refer to Service limit.) (2) Pull out the entire rack to allow viewing of the teeth, and check for damage. Even if abnormality is found in either (1) or (2), replace the entire gearbox. Replace the gearbox with a new part. If the free play of rack shaft in radial direction is out of the specified range, replace the gearbox with new part. (Refer to Service limit.) If the free play of input shaft in radial and axial direction is out of the specified range, replace the gearbox with a new part. (Refer to Service limit.) Replace. Replace. Replace. Replace. Replace. Replace. Replace.
Rack & pinion
Poor mating of rack with pinion
(1) Bending of the rack shaft (2) Bending of the cylinder portion (3) Crack or damage on the cast iron portion 4 Gearbox unit (4) Wear or damage on rack bushing (5) Wear on input shaft bearing 5 6 7 8 9 10 11 Boot Tie-rod Tie-rod end Adjusting screw spring Boot clip Sleeve Pipe Crack, damage or deterioration (1) Looseness of ball joint (2) Bend of tie-rod Damage or deterioration of dust seal Deterioration Deterioration Damage (1) Damage to flared surface (2) Damage to flare nut (3) Damage to pipe
2. SERVICE LIMIT
Make a measurements as follows. If it exceeds the specified service limits, adjust or replace. NOTE: When making a measurement, vise the gearbox using ST. Never vise the gearbox by inserting aluminum plates etc. between vise and gearbox. ST1 926200000 STAND ST2 34199AG000 BOSS D
PS-34
Steering Gearbox
3. RACK SHAFT PLAY IN THE RADIAL DIRECTION

Right-turn steering: Service limit 0.12 mm (0.005 in) or less On condition Weighting point L1: 10 mm (0.39 in) P: 98 N (10 kgf, 22 lb) Measuring point L2: 25 mm (0.98 in)
L2 L1
5. TURNING RESISTANCE OF GEARBOX

Using the ST, measure the gearbox turning resistance. ST 34099PA100 SPANNER Service limit: Maximum allowable resistance: 11.3 N (1.15 kgf, 2.54 lb) or less. Difference between right and left turning resistance: 24% or less
PS-00105
PS-00769
4. INPUT SHAFT PLAY

In radial direction: Service limit 0.26 mm (0.01 in) or less On condition P: 98 N (10 kgf, 22 lb)
P
PS-00103
In axial direction: Without play
PS-00104
PS-35
Steering Gearbox
6. OIL LEAKAGE
b
(5)
(6) (1) (4) (3) (2) c d
e g d g
PS-00622
(1) (2)
Power cylinder Cylinder
(3) (4)
Rack piston Rack axle
(5) (6)
Input shaft Valve housing
1) Lift up the vehicle. 2) If a fluid leak is found, clean the fluid completely from the suspect area, and turn the steering wheel approx. 30 to 40 times to the left and right from lock to lock, with the engine running, and check again for leaks immediately, and also after a few hours have passed. 3) Cause and solution for oil leakage from a The oil seal is damaged. Replace the valve assembly with a new part. 4) Cause and solution for oil leakage from b The torsion bar O-ring is damaged. Replace the valve assembly with a new part. 5) Cause and solution for oil leakage from c The oil seal is damaged. Replace the valve assembly or oil seal with a new part. 6) Cause and solution for oil leakage from d The pipe is damaged. Replace the faulty pipe or Oring. 7) Cause and solution for oil leakage from g. The hose is damaged. Replace the hose with a new part.
8) If leak is other than a, b, c, d or g, or if oil is leaking from gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove fluid from surrounding portions. Then, turn the steering wheel from lock to lock about 30 to 40 times with the engine running, then re-inspect the leaking area immediately after and several hours after this operation. (1) Leakage from e The cylinder seal is damaged. Replace the rack bushing with a new part. (2) Leakage from f There are two possible causes. Perform the following step first. Remove the pipe assembly B from the valve housing, and close the circuit using ST. ST 926420000 PLUG Turn the steering wheel from lock to lock approx. 30 to 40 times with the engine running, then inspect the leaked portion immediately after and several hours after this operation. If leakage from f is noted again: The oil seal of pinion and valve assembly is damaged. Replace the pinion & valve assembly with a new part. Or replace the oil seal and the parts that are damaged during disassembly with new parts. If oil stops leaking from f: The oil seal of rack housing is damaged. Replace the oil seal and parts that are damaged during disassembly with new parts.
PS-36
Steering Gearbox
F: ADJUSTMENT
1) Adjust the front toe. <Ref. to FS-10, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.> Standard of front toe: IN 3 OUT 3 mm (IN 0.12 OUT 0.12 in)
PS-00107
(1) Lock nut
2) Adjust the steering angle of the wheels. Standard of steering angle:

Except for 2.5 GT spec.B and 3.0 R-LTD Inner wheel 37.6r1.5 Outer wheel 33.0r1.5 Model 2.5 GT spec.B and 3.0 R-LTD 33.8r1.5 30.2r1.5
3) If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position, or error is more than 5 on the periphery of the steering wheel, correctly re-install the steering wheel.
(1)
PS-00513
(1) 5 or less
4) If the steering wheel spokes are not horizontal with vehicle set in the straight ahead position after this adjustment, correct it by turning the right and left tie-rods in the opposite direction from each other by the same angle.
PS-37
Pipe Assembly
6. Pipe Assembly
A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Lift up the vehicle, and then remove the front crossmember support plate and jack-up plate. Large type
4) Remove the clamp E from return hose and pressure hose.
(3)
(2) (1)
PS-00537
(1) PS-00445
(1) Return hose (2) Pressure hose (3) Clamp E
(1) Front crossmember support plate
5) Disconnect the pipe D from return hose and pipe C from pressure hose.
Small type
(4) (3) (2) (1) (1) FS-00105 (2)
(1)
3) Remove the one pipe joint at the center of the gearbox, and connect the vinyl hose to the pipe and the joint. Discharge the fluid by turning the steering wheel fully clockwise and counterclockwise. Discharge the fluid similarly from other pipes.
PS-00538
(1)
(1) (2) (3) (4)
(2) PS-00553
6) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Duct.>
PS-38
Pipe Assembly
7) Disconnect the suction hose and pressure hose from oil pump.
B: INSTALLATION
1) Temporarily tighten the hose bracket bolt.
(1) (2) (1)
(2)
PS-00460
PS-00624
(1) Suction hose (2) Pressure hose
(1) Hose ASSY (2) Hose bracket
8) Disconnect the suction hose and return hose from the reservoir tank.
(3)
2) Install the plastic clip to the pressure hose and suction hose. CAUTION: Align the installation position of the plastic clip with the protector edge of the suction hose.
(2)
(1) (2) (1) PS-00799 (3)
(1) Reservoir tank (2) Suction hose (3) Return hose
(4) PS-00455
9) Remove the hose bracket and take out the hose assembly from vehicle.
(1) (2) (3) (4)
Plastic clip Protector Suction hose Pressure hose
(2) (1)
PS-00624
PS-39
Pipe Assembly
3) Connect the suction hose and return hose to the reservoir tank. CAUTION: Firmly insert the plastic clip of return hose to the bracket.
(3)
5) Temporarily connect pressure hose and pipe C, and the return hose and pipe D. Place clamp E at the position shown in the figure, and tighten the bolt temporarily.
(1) (2)
(3)
(1) (2)
PS-00799 (6)
(4) (5)
4) Connect the suction hose and pressure hose to the oil pump. Tighten the eye bolt of pressure hose. Tightening torque: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
PS-00539
(1)
(2)
(1) (2) (3) (4) (5) (6)
Return hose Pressure hose Approx. 18 mm (0.71 in) Clamp E Pipe C Pipe D
6) Tighten clamp E.
PS-00460
Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb) 7) Tighten the pressure hose and pipe C, and the return hose and pipe D. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
PS-40
Pipe Assembly
8) Connect pipes A and B to the four pipe joints of the gearbox. Tightening torque: Refer to COMPONENT of General Description. <Ref. to PS-4, POWER ASSISTED SYSTEM, COMPONENT, General Description.>
(1)
(2) PS-00553
9) Install the front crossmember support plate and jack-up plate. 10) Lower the vehicle. 11) Tighten the bolts which hold the hose bracket. Tightening torque: 10 Nm (1.02 kgf-m, 7.4 ft-lb)
(2) (1)
PS-00624
12) Install the air intake duct. <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Duct.> 13) Connect the ground cable to battery. 14) Fill with the specified fluid. CAUTION: Never start the engine before filling with fluid; otherwise the vane pump may become seized. 15) Finally, check the clearance between pipes or hoses as shown in the figure indicated in General Diagnostic Table. <Ref. to PS-58, INSPECTION OF CLEARANCE, INSPECTION, General Diagnostic Table.>
PS-41
Pipe Assembly
C: INSPECTION
Check all disassembled parts for wear, damage or other problems. Repair or replace the defective parts as necessary.
Part Pipe Clamp Maintenance parts O-ring fitting surface damage Nut damage Pipe damage Loose clamps Flare surface damage Flare nut damage Outer surface cracks Outer surface wear Clip damage End coupling or adapter deformation Corrective action Replace with a new part. Replace with a new part.
Hose
Replace with a new part.
CAUTION: Although the surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are to be very shortened. Wipe off hoses immediately if any of these come into contact with the hoses. Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspection frequently when the vehicle is used in hot weather areas, cold weather areas and a driving condition in which many steering operations are required in short time. Continuous discharge of the relief valve for 5 seconds or more will reduce the service lives of hoses, oil pump, fluid, etc., due to over heating.
Trouble Pressure hose burst Possible cause Excessive holding time of relief status Malfunction of the relief valve Poor cold characteristic of fluid Improper connection Loosening of the clip Poor cold characteristic of fluid Wrong layout, tensioned Excessive play of engine due to deterioration of engine mounting rubber Improper stop position of pitching stopper Excessive holding time of relief status Excessive tightening torque for return hose clip Power steering fluid, engine oil, electrolyte adhere on the hose surface Too many uses in extremely cold weather Corrective action Instruct customers. Replace the oil pump. Replace fluid. Repair. Retighten. Replace fluid. Replace the hose. Replace the parts if defective. Replace the parts if defective. Replace. Instruct customers. Replace. Replace. Be careful during service work. Replace. Instruct customers.
Disconnection of the return hose
Fluid slightly leaking out of hose
Crack on hose
PS-42
Pipe Assembly
NOTE: There are conditions in which a fluid leak is diagnosed, but is not actually leaking. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
(7)
(11)
(15) (8) (19) (2) (3)
(14)
(16) (18) (17)
(12)
(21) (1) (20)
(4) (5) (6) (10) (13) (9)
PS-00805
Fluid leaking area
Leakage from pipe and hose connections numbered with (1) through (8) in the figure
Possible cause Insufficient tightening of flare nut, adhesion of dirt, damage to flare or flare nut or eye bolt Improper installation of hose or clamp Damaged O-ring or gasket Crack or damage in hose Crack or damage in hose hardware Damaged O-ring Damaged gasket Crack in oil tank Damaged cap gasket Crack in root of filler neck Fluid level too high Damaged oil seal Damaged gasket or oil seal Damage in control valve
Leakage from hose (9) through (13) in the figure Leakage from surrounding of cast iron portion of oil pump, (14) and (15) in the figure Leakage from oil tank, (16) and (17) in the figure Leakage from filler neck of (18) Leakage from power cylinder of gearbox area (19) in the figure Leakage from (20), (21) in the figure and control valve of gearbox
Corrective action Loosen and retighten. Replace if ineffective. Retighten or replace the clamp. Replace the O-ring, gasket pipe or hose with new part, if still no improvement, replace the gearbox as well. Replace with a new part. Replace with a new part. Replace the oil pump. Replace the oil pump. Replace the oil tank. Replace the cap. Replace the oil tank. Adjust the fluid level. Replace the oil seal. Replace the problem parts. Replace the control valve.
PS-43
Oil Pump
7. Oil Pump
A: REMOVAL
1. H4 MODEL
1) Disconnect the ground cable from the battery. 2) Remove the air intake duct. <Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Duct.> 3) Remove the pulley belt cover. 4) Loosen the belt tension securing bolt and generator securing bolt, then remove the power steering pump V-belt.
Turbo model
(1)
(2)
PS-00459
7) Remove the installation bolt of the power steering pump bracket.
PS-00461
5) Disconnect the connector from the power steering pressure switch. 6) Disconnect the pressure hose and suction hose from the oil pump. CAUTION: Do not allow fluid to come into contact with the pulley belt. To prevent foreign matter from entering the hose and pipe, cover the open ends with clean cloth. Non-turbo model
(1)
PS-00188
8) Place the oil pump bracket in a vise, and remove the two bolts from the front side of the oil pump. CAUTION: When securing the oil pump bracket in a vise, hold the oil pump bracket with the least possible force between two pieces of wood.
(2)
PS-00128 PS-00688
9) Remove the bolt from the rear side of oil pump.
PS-44
Oil Pump
10) Disassemble the oil pump and bracket by inserting a flat tip screwdriver as shown in the figure.
8) Place the oil pump bracket in a vise, and remove the two bolts from the front side of the oil pump. CAUTION: When securing the oil pump bracket in a vice, hold the oil pump bracket with the least possible force between two pieces of wood.
PS-00129
2. H6 MODEL
1) Disconnect the ground cable from the battery. 2) Remove the cover of the pulley belt. 3) Remove the V-belts. 4) Remove the power steering pressure switch connector. 5) Remove the tensioner adjuster. 6) Disconnect the pressure hose and suction hose from the oil pump. CAUTION: Do not allow fluid to flow from the hose end and contact the pulley belt. To prevent foreign objects from entering the hose, cover the hose openings with a clean cloth.
PS-00702 (1)
PS-00229
9) Remove the bolt from the back side of the oil pump.
10) Remove the oil pump from the bracket.
(2)
PS-00700
7) Remove the bolts which holds the power steering pump bracket.
PS-00701
PS-45
Oil Pump
B: INSTALLATION
1. H4 MODEL
1) Install the oil pump to the bracket. Tightening torque: 15.7 Nm (1.6 kgf-m, 11.6 ft-lb)
4) Connect the pressure hose and suction hose. Tightening torque: Eye bolt 40 Nm (4.1 kgf-m, 29.5 ft-lb) CAUTION: Be careful not to twist hoses. Twisted hoses may contact other parts. Non-turbo model
(1)
(2) PS-00128

PS-00688
Turbo model
(1) PS-00137
2) Attach the installation bolts of the power steering pump bracket. Tightening torque: <Ref. to PS-6, OIL PUMP, COMPONENT, General Description.>
(2) PS-00459
5) Connect the power steering pressure switch connector. 6) Install the V-belts to the oil pump. 7) Check the tension of the V-belt. <Ref. to ME(H4SO)-40, INSPECTION, V-belt.> 8) Tighten the lock bolt of the belt tension nut.
PS-00188
3) After installing the oil pump, fill the fluid while rotating the pulley by hand to bleed air from the oil pump. CAUTION: Always fill the oil pump with the fluid to prevent abnormal noise and seizure of the oil pump.
Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb) 9) Install the pulley belt cover. 10) Install the air intake duct. <Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4SO)-8, INSTALLATION, Air Intake Duct.> 11) Connect the ground cable to battery.
PS-46
Oil Pump
12) Fill with the specified power steering fluid. <Ref. to PS-53, Power Steering Fluid.> CAUTION: Never start the engine before filling with fluid; otherwise the vane pump may become seized.
3) After installing the oil pump, fill the fluid while rotating the pulley by hand to bleed air from the oil pump. CAUTION: Always fill the oil pump with the fluid to prevent abnormal noise and seizure of the oil pump. 4) Connect the pressure hose and suction hose. Tightening torque: Eye bolt 40 Nm (4.1 kgf-m, 29.5 ft-lb) CAUTION: Be careful not to twist hoses. Twisted hoses may contact other parts.
(1)
2. H6 MODEL
1) Install the oil pump to the bracket. Tightening torque: 15.7 Nm (1.6 kgf-m, 11.6 ft-lb)
PS-00229
(2)
PS-00700
PS-00702
2) Tighten the bolt which attaches the power steering pump bracket. Tightening torque: <Ref. to PS-6, OIL PUMP, COMPONENT, General Description.>
5) Connect the power steering pressure switch connector. 6) Install the tensioner adjuster. 7) Install the V-belts. 8) Install the pulley belt cover. 9) Connect the ground cable to battery. 10) Pour the specified power steering fluid. <Ref. to PS-53, Power Steering Fluid.> CAUTION: Never start the engine before filling with fluid; otherwise the vane pump may become seized.
PS-00701
PS-47
Oil Pump
C: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and replace faulty parts.
No. Parts Inspection (1) Crack, damage or oil leakage (2) Play of pulley shaft (1) Damage 2 Pulley (2) Bend Corrective action Replace the oil pump with a new part. Measure the radial play and axial play. If any of these exceeds the service limit, replace the oil pump with a new part. Replace with a new part. Measure the V groove deflection. If it exceeds the service limit, replace the pulley with a new part. Check the rotating resistance of pulley. If it exceeds the service limit, replace the oil pump with new part. If the a string is wrapped on the pulley and rotated, and the oil pump emits a noise that is markedly different in tone and loudness from a sound of a new oil pump, replace the oil pump with a new part. Replace with a new part. Replace with a new part.
Oil pump (Exterior)
(1) Faulty or seized of vane pump 3 Oil pump (Interior) (2) Bend in the shaft or damage to bearing 4 5 O-ring Bracket Cracking or deterioration Crack
PS-48
Oil Pump
2. SERVICE LIMIT
Make a measurements as follows. If it exceeds the service limit, replace with a new part. CAUTION: When securing the oil pump on a vise, hold the oil pump with the least possible force between two pieces of wood. Do not set the outside of flow control valve or pulley on a vise; otherwise outside or pulley might be deformed. Select properly sized wood pieces. 1) Play of the pulley shaft Condition: P: When applying the force of 9.8 N (1.0 kgf, 2.2 lb) Service limit: Play in the radial direction (Direction 0.4 mm (0.016 in) or less
(1)
2) Deflection of the pulley groove Service limit: 1.0 mm (0.039 in) or less NOTE: Read the value for one surface of V ditch, and then the value for another off the dial gauge.
PS-00147
(1) Dial gauge
3) Rotating resistance of pulley Service limit: Maximum load: 9.22 N (0.94 kgf, 2.07 lb) or less NOTE: A rather higher value may be indicated when pulley starts turning. Measure the load during rotation to make a judgment.
PS-00145
(1) Dial gauge
Axial play (Direction ) 0.9 mm (0.035 in) or less

(1)
PS-00148
(1) Spring scale
PS-00146
(1) Dial gauge
PS-49
Oil Pump
3. HYDRAULIC PRESSURE
NOTE: To measure hydraulic pressure correctly, be sure to complete all the items in INSPECTION, prior to performing the measurement. <Ref. to PS54, INSPECTION, General Diagnostic Table.> Do not leave the valve of pressure gauge closed or hold the steering wheel at lock for 5 seconds or more in any case, this can damage the oil pump. Before attaching a pressure gauge, place a waste cloth at locations where fluid can be expected to spill. Wipe off any spilt fluid completely after the measurement. 1) Regular pressure measurement (1) Connect the ST1, ST2 and ST3. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A (2) Remove the air intake duct. (3) Disconnect the pipe C from pump. (4) Using the gasket (Part No. 34621AC021) and bolt (Part No. 34620AC010), attach the ST2 to pump instead of pressure hose. Non-turbo model
(1)
(7) Open the valve, and start the engine. (8) Measure the regular pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A
PS-00152
(1) Valve
(2)
Service limit: 981 kPa (10 kg/cm2, 142 psi) or less (9) If it is not within the specification, replace the problem part for the following problems. (Pipe or hose clogged, leaks from fluid line, and mixture of foreign matter in fluid line) 2) Measure the relief pressure. (1) Using the STs, measure the relief pressure. (2) Close the valve. (3) Measure the relief pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A
PS-00688
Turbo model
PS-00153 (1)
(1) Valve
(2)
PS-00459
(5) Attach the ST3 to the end of pressure hose which is removed from pump. (6) Replenish power steering fluid up to the specified level.
Service limit: H4 non-turbo model: 7,350 8,050 kPa (75 82 kg/cm2, 1,067 1,165 psi) H4 turbo model: 8,100 8,800 kPa (83 90 kg/cm2, 1,174 1,276 psi) H6 model: 8,300 9,000 kPa (85 92 kg/cm2, 1,204 1,305 psi) (4) If it is not within the specification, replace the oil pump.
PS-50
Oil Pump
3) Measure the working pressure. (1) Using the ST, measure the working pressure. (2) Open the valve. (3) Measure the working pressure of control valve by turning steering wheel from stop to stop. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A
PS-00152
(1) Valve
Service limit: 7,650 8,330 kPa (78 85 kg/cm2, 1,110 1,208 psi) (4) If it is out of specification, measure the steering effort. <Ref. to PS-57, MEASUREMENT OF STEERING EFFORT, INSPECTION, General Diagnostic Table.> If it is not within specification, replace the control valve itself or control valve and pinion as a single unit, using new parts.
PS-51
Reservoir Tank
8. Reservoir Tank
A: REMOVAL
1) Drain fluid from the reservoir tank. 2) Disconnect the hose from reservoir tank. CAUTION: To prevent foreign matter from entering the hose and pipe, cover the open ends of them with clean cloth.
(3)
(1) (2)
PS-00799
3) Remove the reservoir tank from the body.
B: INSTALLATION
1) Install the reservoir tank to the body. Tightening torque: 13 Nm (1.32 kgf-m, 9.6 ft-lb) 2) Connect the hose to the reservoir tank.
(3)
(1) (2)
PS-00799
3) Replenish power steering fluid up to the specified level. <Ref. to PS-53, Power Steering Fluid.>
C: INSPECTION
Check the reservoir tank for cracks, breakage or damage. If a failure is found, replace the reservoir tank.
PS-52
Power Steering Fluid

9. Power Steering Fluid

A: SPECIFICATION
Recommended power steering fluid SUBARU ATF or ATF DEXRON III
C: REPLACEMENT
1) Lift up the vehicle. 2) Remove the crossmember support. 3) Remove the pipe joint in the center of gearbox, and connect the vinyl hose to the pipe and joint. Wipe fluid off while turning the steering wheel. 4) Add the specified fluid to reservoir tank at MAX level. 5) Continue to turn the steering wheel slowly from lock to lock until the bubbles stop appearing on oil surface while keeping the fluid at the level in the Step 4). 6) If the steering wheel is turned in a low fluid level condition, air will be sucked into the pipe. If air has entered, leave it for about half an hour and then repeat step 5) again. 7) Start the engine and let it idle. 8) Continue to turn the steering wheel slowly from lock to lock again until the bubbles stop appearing on oil surface, while keeping the fluid at the level in Step 4). Normally bubbles will stop appearing after turning the steering wheel from lock to lock three times. 9) In case bubbles do not stop appearing in the tank, leave it for about half an hour and then repeat from step 4) again. 10) Lower the vehicle, and then idle the engine. 11) Continue to turn the steering wheel from lock to lock until the bubbles stop appearing and change of the fluid level is within 3 mm (0.12 in). 12) In case the following happens, leave it about half an hour and then perform step 8) to 11) again. (1) The fluid level changes by 3 mm (0.12 in) or more. (2) Bubbles remain on the upper surface of the fluid. (3) Grinding noise is generated from oil pump. 13) Check the fluid leakage after turning steering wheel from lock to lock with engine running.
B: INSPECTION
1) Check the power steering fluid for deterioration or contamination. If the fluid is highly deteriorated or contaminated, drain it and refill with new fluid. 2) Check the joints and units for oil leakage. If any oil leaks are found, repair or replace the applicable part. 3) Inspect the fluid level of reservoir tank with vehicle on level surface and engine stopped. If the level is at MIN. point or below, add fluid to keep the level in the specified range of the indicator. If fluid level is at MAX. point or above, drain fluid by using a syringe or the like. (1) Check at power steering fluid temperature 20C (68F); read the fluid level on the COLD side. (2) Check at power steering fluid temperature 80C (176F); read the fluid level on the HOT side.
HOT MAX COLD MAX HOT MIN COLD MIN PS-00463
PS-53


A: INSPECTION
Trouble Steering effort is heavy in all ranges. Steering effort is heavy at stand still. Steering wheel vibrates when turning. Possible cause 1. Pulley belt Unequal length of pulley belts Contact with oil or grease Looseness or damage of the pulley belt Poor uniformity of the pulley belt cross section Pulley belt touches to pulley bottom Poor revolution of pulleys (except oil pump pulley) Poor revolution of oil pump pulley 2. Tire and wheel Improper tire out of specifications*1 Improper wheel out of specifications*1 Tires not properly inflated 3. Fluid Low fluid level Air entry in fluid Dust entry in fluid Fluid deterioration Inadequate warm up of fluid *2 4. Idle speed Lower idle speed Excessive drop of idle speed at start or when turning the steering wheel *3 5. Measure the hydraulic pressure. <Ref. to PS-48, INSPECTION, Oil Pump.> 6. Measure the steering wheel effort. <Ref. to PS-57, MEASUREMENT OF STEERING EFFORT, INSPECTION, General Diagnostic Table.> 1. Fluid line Folded hose Flattened pipe 2. Tire and wheel Flat tire Mixed use of different tires Mixed use of different wheels Abnormal wear of tire Unequal tread remaining Unequal pressure of tire 3. Front alignment Improper or unequal caster Improper or unequal toe-in Loose suspension connections 4. Others Damaged joint assembly Unbalanced height Unbalanced weight 5. Measure the steering wheel effort. <Ref. to PS-57, MEASUREMENT OF STEERING EFFORT, INSPECTION, General Diagnostic Table.> Corrective action
Adjust or replace.
Replace or reinflate.
Refill, bleed air, replace or instruct customer.
Adjust or instruct customer.
Replace the problem parts. Adjust or replace. Repair or replace.
Vehicle leads to one side or the other Returning force of steering wheel to center is poor. Steering wheel vibrates when turning.
Adjust, fix or replace.
Adjust or retighten.
Replace, adjust or instruct customer. Adjust or replace.
If the tires or wheels are wider than standard, the load to the power steering system is increased. Accordingly, in a condition, for example before fluid warms-up, relief valve may work before reaching maximum turning angle. In this case, steering effort may be heavy. When the measured hydraulic pressure is normal, there is no abnormal thing. *2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn the steering wheel from stop to stop several times to warm up fluid. If steering effort reduces normally, function is normal. *3 In cold weather or with insufficient warm up of the engine, steering effort may be heavy due to excessive drop of idle rpm when turning the steering wheel. In this case, start the vehicle with increasing engine speed than usual. If steering effort reduces normally, function is normal.
*1
PS-54


CAUTION: Do not keep the relief valve operated for five seconds or more at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature. NOTE: A screeching noise may be heard immediately after the engine start in extremely cold conditions. In this case, if the noise goes off during warm up there is no abnormal function in the system. This is due to the fluid characteristics in extremely cold condition. The oil pump normally makes a small whining noise due to its mechanism. Even if a noise is heard when steering wheel is turned at stand still, there is no abnormal function in the system provided that the noise eliminates when the vehicle is driving. When turning the steering wheel with the brake applied when the vehicle is parked, a screeching noise may be generated by the brake disc and pads. This is not a fault in the steering system. There may be a small vibration around the steering devices when turning the steering wheel at standstill, even though the component parts are operating properly. Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of combined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature and braking condition. These conditions do not indicate a problem in the system. Confirm vibration for an AT model, by applying the parking brake on a concrete surface, shifting into the D range, and turning the steering wheel repeatedly from slow to rapid, step by step.
Trouble Possible cause Relief valve emits operating sound when steering wheel is completely turned in either direction. (Do not keep this condition for five seconds or more.) Relief valve emits operating sound when steering wheel is not turned. This means that the relief valve is defective. Interference with adjacent parts Loosened installation of oil pump, oil tank, pump bracket, gearbox or crossmember Loose oil pump pulley or other pulley(s) Looseness of linkage, play of steering, improper tightening (looseness) of suspension joint or steering column Sound generates from the inside of gearbox or oil pump. Knocking When turning steering wheel in both directions with small angle repeatedly at engine ON or OFF. Excessive backlash Loosened lock nut for adjusting backlash Insufficient tightening or play in the tie-rod or tie-rod end Air in vane pump Grinding noise (continuous) While engine is running. Vane pump seizing Oil pump pulley bearing seized Folded hose, flattened pipe Improper adjustment of pulley belt Damaged or over tensioned pulley belt Unequal length of pulley belts Warpage or dirty V-groove surface of oil pump pulley Corrective action Normal operation Replace the oil pump. Check the clearance. Correct if necessary. <Ref. to PS-42, INSPECTION, Pipe Assembly.> Retighten. Retighten. Retighten or replace. Replace faulty parts in the gearbox or oil pump. Adjust and retighten. Retighten or replace. Inspect and retighten the fluid line connection. Refill the fluid and vent air. Replace the oil pump. Replace the oil pump. Replace. Adjust or replace. (Replace two belts as a set.) Clean or replace.
Hiss noise (continuous) While engine is running.
Rattling noise (intermittent) While engine is running.
Squeal, squeak (intermittent or continuous) While engine is running.
PS-55

Trouble Fluid aeration Sizzling noise (continuous) While engine is running. Damaged pipe of gearbox Faulty inside of hose or pipe Flattened hose or pipe Abnormal inside of oil tank Removed oil tank cap Possible cause Corrective action Fix the faulty part causing aeration. Replace the fluid and vent air. Replace the pipe. Correct or replace.
Whistle (continuous) While engine is running.
Whine or growl (intermittent or continuous) While engine is running with/ without steering turned.
Replace. Install cap. Replace the faulty parts of the Faulty pipe of gearbox or faulty hose gearbox or the hose. Looseness of oil pump, oil pump bracket attachment Retighten. Replace the oil pump or hose, if the noise can be heard when Fault inside of oil pump or hose vehicle is running as well as being stopped. Remove the power steering pulTorque converter growl, air conditioner compression growl ley belt and check. Fault inside of gearbox Faulty steering shaft bearing Occurs when turning the steering wheel with brakes (service or parking) applied. Engine speed is too low. Air in vane pump Damaged valve in oil pump or gearbox Excessive play in steering, looseness of suspension parts Replace the faulty parts of gearbox. Apply grease or replace. If the noise goes off when brake is released, it is normal. Adjust, and notify customer. Repair faulty part Vent air. Replace the faulty parts in gearbox and oil pump. Retighten.
Grinding noise (continuous) While engine is running with the steering turned.
Vibration While engine is running with/ without steering turned.
PS-56

2. MEASUREMENT OF STEERING EFFORT

1 Step CHECK STEERING EFFORT. 1) Stop the vehicle on paved road. 2) Start the engine. 3) Idle the engine. 4) Install a spring scale on the steering wheel. 5) Pull the spring scale at a right angle to the steering wheel, and measure both right and left steering wheel efforts. NOTE: When turning the steering more quickly than necessary from a direction to the other direction at an engine speed of 2,000 rpm or more, steering effort may be heavy. This is caused by flow characteristic of the fluid in the oil pump and is not a defect. CHECK STEERING EFFORT. 1) Stop the engine. 2) Pull the spring scale at a right angle to the steering wheel, and measure both right and left steering wheel efforts. CHECK STEERING WHEEL EFFORT. 1) Remove the universal joint. 2) Measure the steering wheel effort. CHECK STEERING WHEEL EFFORT. Measure the steering wheel effort. CHECK UNIVERSAL JOINT. Measure the swing torque of the joint (yoke of steering column side). <Ref. to PS-15, INSPECTION, Universal Joint.> CHECK UNIVERSAL JOINT. Measure the swing torque of the joint (yoke of gearbox side). <Ref. to PS-15, INSPECTION, Universal Joint.> CHECK FRONT WHEEL. Check the front wheels. Check Is the steering effort less than 29.4 N (3.0 kgf, 6.6 lb)? Yes Go to step 2. No Adjust the backlash.
Is the steering effort less than 294.2 N (30 kgf, 66.2 lb)?
Go to step 3.
Perform the adjustment.
Is the steering effort less than 2.26 N (0.23 kgf, 0.51 lb)? Is the difference of steering effort between right and left less than 20%? Is the swing torque of the universal joint less than 7.3 N (0.74 kgf, 1.64 lb)? Is the swing torque of the universal joint less than 3.8 N (0.39 kgf, 0.86 lb)?
Go to step 4.
Go to step 5.
Go to step 6.
Check, adjust and replace if necessary. Check, adjust and replace if necessary. Replace with a new part.
Go to step 7.
Replace with a new part.
10
Does the front wheels have unsteady revolution or rattling, or does the brake drag? CHECK TIE-ROD ENDS. If the tie-rod ends of suspenRemove the tie-rod ends. sion have unsteady revolution or rattling? CHECK BALL JOINT. If the ball joints of suspension Remove the ball joint. have unsteady revolution or rattling? Is the rotating resistance of steerCHECK GEARBOX. ing gearbox less than 11.3 N Measure the rotating of gearbox. <Ref. to PS-35, TURNING RESISTANCE OF (1.15 kgf, 2.54 lb)? Is the differGEARBOX, INSPECTION, Steering Gearbox.> ence between right and left sides less than 24%?
Inspect, readjust and replace if necessary. Inspect and replace if necessary. Inspect and replace if necessary. Steering effort is normal.
Go to step 8.
Go to step 9.
Go to step 10.
Readjust the backlash, and if ineffective, replace the faulty parts.
PS-57

3. INSPECTION OF CLEARANCE
This table lists various clearances that must be correctly adjusted to ensure the normal vehicle driving without interfering noise, or any other faults.
Location (1) Crossmember to Hose ASSY (2) Front exhaust pipe to Hose ASSY (Turbo model) (3) Front frame side to Hose ASSY (4) Turbo cover to Hose ASSY (Turbo model) (5) Master cylinder to Return hose (Turbo model) (6) Master cylinder to Hose clip (Model with vehicle dynamics control (VDC)) (7) VDC H/U to Hose ASSY (Model with vehicle dynamics control (VDC)) (8) Air cleaner to Hose ASSY (Turbo model) (9) Air boot to Hose ASSY (10) Protector to Hose ASSY (Turbo model, DOHC non-turbo model) (11) Blow-by hose to Hose ASSY (Turbo model) (12) Over flow hose to Hose ASSY (Turbo model) (13) Brake pipe to Return hose (Model with ABS) (14) Front suspension bracket to Return hose (15) Front wheel apron to Return hose (16) VDC H/U bracket to Suction hose (Model with vehicle dynamics control (VDC)) (17) Air cleaner case to Suction hose (18) Air intake duct to Suction hose (Turbo model) (19) Air duct to Suction hose (Turbo model) (20) Front wheel apron to Reservoir tank (21) VDC H/U to Reservoir tank (Model with vehicle dynamics control (VDC)) (22) Valve housing to DOJ (MT model) (23) Valve housing to Crossmember (Hole) (24) Bracket to Crossmember (25) Cylinder to Crossmember (26) Elbow to Crossmember (27) Cylinder to Exhaust pipe (28) Universal joint coupling to Turbo cover (Turbo model) (29) Universal joint column side yoke to Master cylinder (Closest point of approach when the universal joint turns by 360) (OUTBACK model) (30) Cruise control to Hose ASSY (Model with cruise control) (31) Universal joint coupling to ATF level gauge (32) Boot to Exhaust pipe (33) Return hose to Pressure hose Minimum allowance mm (in) 3 (0.12) 15 (0.59) 10 (0.39) 10 (0.39) 10 (0.39) 10 (0.39) 5 (0.20) 5 (0.20) 10 (0.39) 10 (0.39) 8 (0.31) 8 (0.31) 10 (0.39) 5 (0.20) 5 (0.20) 5 (0.20) 5 (0.20) 10 (0.39) 10 (0.39) 5 (0.20) 5 (0.20) 12 (0.47) 1 (0.04) 1 (0.04) 5 (0.20) 1 (0.04) 18 (0.71) 15 (0.59) 5 (0.20) 10 (0.39) 10 (0.39) 18 (0.71) No contact between hoses
PS-58

(19) (12) (18)
(8),(9)
(17)
(27) (32) (24) (26)
(10),(11),(16) (1) (2) (7) (3) (21) (20)
(13),(14)
(22) (23) (25)
(6)
(15)
(5) (28),(31) (29) (4) (30) (33)
PS-00772
PS-59

PS-60
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
A: SPECIFICATION
1. HEATER SYSTEM
Item Specification On condition Mode selector switch: HEAT Temperature control switch: FULL HOT Temperature difference between hot water and inlet air: 65C (149F) How water flow rate: 360 2 (95.1 US gal, 79.2 Imp gal)/h Heat mode (FRESH), FULL HOT at 12.5 V Temperature control switch: FULL COLD Blower fan speed: Auto A/C: 6th position Manual A/C: 4th position Mode selector lever: RECIRC 12 V
Heating capacity
5.1 kW (4,385 kcal/h, 17,401 BTU/h) or more
Air flow rate
320 m3 (11,301 cu ft)/h
Max air flow rate
510 m3 (18.01 cu ft)/h
Heater core size (height length width) Type Blower motor Fan type and size (diameter width)
264 110 27 mm (10.4 4.33 1.06 in) Magnet motor 220 W or less Sirocco fan type 150 75 mm (5.91 2.95 in)
2. A/C SYSTEM
Auto A/C model
Item Type of air conditioner Cooling capacity Refrigerant Type Discharge Max. permissible speed Type Power consumption Type of belt Pulley dia. (effective dia.) Pulley ratio Type Core face area Core thickness Radiation area Effective inner capacity Type Type Dimensions (W H T) Fan type Outer diameter width Power consumption Specification Reheat air-mix type 5.3 kW (4,557 kcal/h, 18,084 BTU/h) HFC-134a (CH2FCF3) [0.4r0.03 kg (0.88r0.07 lb)] Scroll, constant volume (SCSA 08C) 74.5 cc (4.55 cu in)/rev 9,000 rpm Dry, single-disc type 35 W 2.5 L SOHC Non-turbo and 2.5 L DOHC Turbo model: V-belt 4 PK 3.0 L DOHC Non-turbo model: V-belt 6 PK 93 mm (3.7 in) 1.43 Corrugated fin (Sub cool type) 0.193 m2 (2.077 sq ft) 16 mm (0.63 in) 5.72 m2 (61.57 sq ft) 190 cm3 (11.6 cu in) Externally equalizing Single tank 298.6 151 38 mm (11.76 5.94 1.50 in) Sirocco fan 150 75 mm (5.91 2.95 in) 220 W
Compressor
Magnet clutch
Condenser
Receiver drier Expansion valve Evaporator
Blower fan
AC-2
General Description
Item Motor type Power consumption Condenser fan (Sub fan) Fan outer diameter Motor type Power consumption Radiator fan (Main fan) Fan outer diameter Specification Magnet 2.5 L SOHC Non-turbo model: 90 W 2.5 L DOHC Turbo model: 120 W 3.0 L DOHC Non-turbo model: 160 W 2.5 L SOHC Non-turbo model: 300 mm (11.8 in) 2.5 L DOHC Turbo and 3.0 L DOHC Non-turbo model: 320 mm (12.6 in) Magnet 2.5 L SOHC Non-turbo model: 90 W 2.5 L DOHC Turbo model: 120 W 3.0 L DOHC Non-turbo model: 160 W 2.5 L SOHC Non-turbo model: 300 mm (11.8 in) 2.5 L DOHC Turbo and 3.0 L DOHC Non-turbo model: 320 mm (12.6 in) 2.5 L Non-turbo MT model (no load): 650r100 rpm 2.5 L Non-turbo MT model (A/C ON): 850r100 rpm 2.5 L Non-turbo AT model (no load): 700r100 rpm 2.5 L Non-turbo AT model (A/C ON): 850r100 rpm 2.5 L turbo MT model (no load): 750r100 rpm 2.5 L turbo MT model (A/C ON): 800r100 rpm 2.5 L turbo AT model (no load): 750r100 rpm 2.5 L turbo AT model (A/C ON): 825r100 rpm 3.0 L model (no load): 650r50 rpm 3.0 L model (A/C ON): 770r50 rpm 196r20 kPa (2.00r0.20 kg/cm2, 28.4r2.9 psi) 225+25 29 kPa (2.29+0.25 0.30 kg/cm2, 32.6+3.6 4.2 psi) 3,140+50 200 kPa +0.51 2 +7.25 (32.02 2.04 kg/cm , 455.4 29.0 psi) 2,550r200 kPa (26.00r2.04 kg/cm2, 369.8r29.0 psi) 1,370r120 kPa (13.97r1.22 kg/cm2, 198.65r17.35 psi) 1,770r80 kPa (18.05r0.82 kg/cm2, 256.81r11.60 psi)
Idle speed
MPFI model
Low-pressure switch operating pressure
ON o OFF OFF o ON ON o OFF OFF o ON ON o OFF OFF o ON
Triple switch (Pressure switch)
High-pressure switch operating pressure
Middle-pressure switch operating pressure
(3) (1)
Thermo-control amplifier working temperature (Evaporator outlet air)
(2) (4)
AC-01681
(1) ON (2) OFF (3) 1C (33.8F) (4) 4+8.0 0C (39.2+46.4 0F)
AC-3
General Description
Manual A/C model

Item Type of air conditioner Cooling capacity Refrigerant Type Discharge Max. permissible speed Type Power consumption Type of belt Pulley dia. (effective dia.) Pulley ratio Type Core face area Core thickness Radiation area Effective inner capacity Type Type Dimensions (W H T) Fan type Outer diameter width Power consumption Motor type Power consumption Fan outer diameter Motor type Power consumption Fan outer diameter MPFI model Specification Reheat air-mix type 5.3 kW (4,557 kcal/h, 18,084 BTU/h) HFC-134a (CH2FCF3) [0.4r0.03 kg (0.88r0.07 lb)] Scroll, constant volume (SCSA 08C) 74.5 cc (4.55 cu in)/rev 9,000 rpm Dry, single-disc type 35 W V-belt 4 PK 93 mm (3.7 in) 1.43 Corrugated fin (Sub cool type) 0.193 m2 (2.077 sq ft) 16 mm (0.63 in) 5.7 m2 (61.57 sq ft) 190 cm3 (11.6 cu in) Externally equalizing Single tank 298.6 151 38 mm (11.7 5.94 1.50 in) Sirocco fan 150 75 mm (5.91 2.95 in) 220 W Magnet 90 W 300 mm (11.8 in) Magnet 90 W 300 mm (11.8 in) 2.5 L Non-turbo MT model (no load): 650r100 rpm 2.5 L Non-turbo MT model (A/C ON): 850r100 rpm 2.5 L Non-turbo AT model (no load): 700r100 rpm 2.5 L Non-turbo AT model (A/C ON): 850r100 rpm 196r20 kPa (2.00r0.20 kg/cm2, 28.4r2.9 psi) 225+25 29 kPa +0.25 2 +3.6 (2.29 0.30 kg/cm , 32.6 4.2 psi) +50 3,140 200 kPa (32.02+0.51 2.04 kg/cm2, 455.4+7.25 29.0 psi) 2,550r200 kPa (26.00r2.04 kg/cm2, 369.8r29.0 psi) 1,370r120 kPa (13.97r1.22 kg/cm2, 198.65r17.35 psi) 1,770r80 kPa (18.05r0.82 kg/cm2, 256.81r11.60 psi)
Compressor
Magnet clutch
Condenser
Receiver drier Expansion valve Evaporator
Blower fan
Condenser fan (Sub fan)
Radiator fan (Main fan)
Idle speed
Low-pressure switch operating pressure
ON o OFF OFF o ON ON o OFF OFF o ON ON o OFF OFF o ON
Triple switch (Pressure switch)
High-pressure switch operating pressure
Middle-pressure switch operating pressure
AC-4
General Description
Item Specification
(3) (1)
Thermo-control amplifier operating temperature (Evaporator outlet air)
(2) (4)
AC-01681
(1) ON (2) OFF (3) 1C (33.8F) (4) 4+8.0 0C (39.2+46.4 0F)
AC-5
General Description
B: COMPONENT
1. HEATER COOLING UNIT
Auto A/C model
T (23) (22) (21) (1)
T (20)
(16)
(5) (6) (2) (4)
(3)
(7) (8)
(17)
(9) (10)
(19)
(15) (13) (12) (11)
(14) (18)
AC-01431
AC-6
General Description
(1) (2) (3) (4) (5) (6) (7) (8) (9) Heater unit case LH Separator Mode door RR Mode door FR Air mix door LH Air mix door RH Heater unit case RH Mode door actuator Evaporator cover (10) (11) (12) (13) (14) (15) (16) (17) (18) Grommet Pipe cover Drain hose Air mix door actuator RH Foot duct RH Expansion valve Evaporator sensor Evaporator Heater core (19) (20) (21) (22) (23) Heater pipe clamp Foot duct LH Heater core cover Air mix door actuator LH Aspirator
AC-7
General Description
Manual A/C model
(20)
(19) (18)
(17)
(1)
(2)
(6) T (4) (13) (14) (3) (5)
(16)
(12)
(11) (15) (7) (8)
(10) (9)
AC-01430
AC-8
General Description
(1) (2) (3) (4) (5) (6) (7) (8) Heater unit case LH Mode door RR Mode door FR Air mix door Heater unit case RH Mode door actuator Evaporator cover Grommet (9) (10) (11) (12) (13) (14) (15) (16) Pipe cover Drain hose Foot duct RH Expansion valve Thermo amplifier Evaporator Heater core Heater pipe clamp (17) (18) (19) (20) Foot duct LH Heater core cover Clip Air mix door linkage
2. BLOWER MOTOR UNIT

(8) T
(1) (7) (9)
(2)
(6) (3)
(4)
(5)
T AC-01130
(1) (2) (3) (4)
Upper case Blower plate Lower case Power Transistor (Auto A/C model) Blower Resistor (Manual A/C model)
(5) (6) (7) (8)
Blower motor Filter cover Control unit (Auto A/C model) Intake door actuator
(9)
Filter
AC-9
General Description
3. CONTROL PANEL
Auto A/C model
(1)
(2)
AC-01131
(1)
Audio ASSY
(2)
Control panel
Manual A/C model

(9) (8)
(10)
(7)
(6)
(5) (4)
(1)
(3) (2)
(1)
AC-01132
(1) (2) (3) (4)
Dial A/C switch FRESH/RECIRC switch Rear window defogger switch
(5) (6) (7)
Heater control panel Mode change switch Switch board
(8) (9) (10)
Heater control base Valve Temperature control cable
AC-10
General Description
4. AIR CONDITIONING UNIT
T2 (2) (6) (5) (6)
T1
(6)
(6) T3 (1) T1 T2
(4)
(6)
(3)
(8)
T1 (6) (7) T3
AC-01432
(1) (2) (3) (4)
Condenser Hose (High-pressure) Hose (Low-pressure) Bracket
(5) (6) (7) (8)
Compressor O-ring Clamp Pipe
AC-11
General Description
5. COMPRESSOR
H4 model
(4)
T3
(5)
T3 T1
T3
(3) (2)
T1
(1) (7)
(6)
T2
AC-00760
(1) (2) (3) (4)
Idler pulley bracket Idler pulley adjuster Idler pulley Compressor upper bracket
(5) (6) (7)
Compressor Compressor lower bracket V-belt
Tightening torque:Nm (kgf-m, ft-lb) T1: 23.0 (2.35, 17.0) T2: 28.9 (2.95, 21.3) T3: 36 (3.7, 26.6)
AC-12
General Description
H6 model
T2
(1)
(2)
T2
T2
(3)
T1
AC-00912
(1) (2) (3)
Compressor upper bracket Compressor Compressor lower bracket
AC-13
General Description
6. HEATER DUCT
(3)
(1) (4) (2)
(5) (6)
AC-00913
(1) (2)
Front defroster nozzle Side ventilation duct (LH)
(3) (4)
Side ventilation duct (RH) Center ventilation duct
(5) (6)
Rear heater duct (LH) Rear heater duct (RH)
AC-14
General Description
C: CAUTION
1. HFC-134A A/C SYSTEM
The cooling system components for the HFC134a system such as the refrigerant and compressor oil are different from the conventional CFC-12 system components and they are incompatible with each other. Vehicles with the HFC-134a system can be identified by the label (A) attached to the vehicle. Before maintenance, check which A/C system is installed to the vehicle.
(A)
4. HANDLING OF REFRIGERANT
The refrigerant boils at approx. 30C (22F). When handling it, be sure to wear protective goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite. If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with plenty of water, and receive medical treatment from an eye doctor. Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside pressure will become extremely high. This may cause the can to explode. If a service can must be warmed up, use warm water of 40C (104F) or less. Do not drop or impact a service can. (Observe the precautions and operation procedure described on the refrigerant can.) When the engine is running, do not open the high-pressure valve of the manifold gauge. Highpressure gas can back-flow resulting in an explosion of the can. Provide good ventilation and do not work in a closed area.
AC-00762
2. COMPRESSOR OIL
HFC-134a compressor oil has no compatibility with that of CFC-12 system. Use only Denso Oil 8, the manufacturer-authorized compressor oil for the HFC-134a system. Do not mix multiple compressor oils. If CFC-12 compressor oil is used in the HFC-134a A/C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts. On the other hand, if HFC-134a compressor oil is used in a CFC-12 A/C system, the durability of the A/C system will be lowered. HFC-134a compressor oil is very hygroscopic. When replacing or installing/removing A/C parts, immediately isolate the oil from atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly closed.
3. REFRIGERANT
CFC-12 refrigerant cannot be used in a HFC134a A/C system. HFC-134a refrigerant, also cannot be used in a CFC-12 A/C system. If an incorrect or no refrigerant is used, it will result in poor lubrication and the compressor itself may be damaged. In order to prevent global warming, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and recycle the gas.
AC-15
General Description
5. O-RING CONNECTIONS
(A) (B)
(C)
(D)
(F) (E)
Always use a new O-ring. In order to keep the O-rings free of lint which can cause a refrigerant gas leak, perform operations without gloves and cloth. Apply compressor oil to O-rings to avoid sticking, before installation. Use a torque wrench to tighten the O-ring fittings. Over-tightening will result in damage of the O-ring and deformation of the pipe end. If the work is interrupted before completing pipe connections, recap the pipes, components and fittings with a plug or tape to prevent foreign matter from entering.
(A)
AC-00007
(A) (B) (C) (D)
Goggles Gloves Avoid open flame No direct heat on container
AC-00008
(A) Seal
(E) Do not discharge (F) Loosen
Visually check the surfaces and mating surfaces of O-rings, threads and connecting points. If a failure is found, replace the applicable parts. Install the O-rings straight against the pipe groove.
(A) (B) (D) (C)
(C)
AC-00009
(A) (B) (C) (D)
O-ring OK NG Groove
AC-16
General Description
Use compressor oil specified in the service manual to lubricate the O-rings. Apply oil to the top and sides of O-rings before installation. Apply compressor oil to the pipe grooves.
AC-00010
After tightening, use a clean cloth to remove excess compressor oil from the connections and any oil which may have run on the vehicle body or other parts. If any leakage is suspected after tightening, do not tighten the connections further, but disconnect the connections, remove the O-rings, and check the O-rings, threads, and connections.
AC-17
General Description
D: PREPARATION TOOL
CAUTION: When working on vehicles with a HFC-134a system, only use HFC-134a specified tools and parts. Do not mix CFC-12 tools and parts. If HFC-134a and CFC-12 refrigerant or compressor oil is mixed, it will result in poor lubrication and the compressor itself may be damaged. In order to prevent the mixture of HFC-134a and CFC-12 parts and liquid, the tool and screw type and the type of service valves used are different. The gas leak detectors for the HFC-134a and CFC-12 systems must also not be interchanged.
Tool & screw type Valve type HFC-134a Millimeter size Quick joint type ILLUSTRATION CFC-12 Inch size Screw-in type Tools and Equipment Wrench Various WRENCHES will be required to service any A/C system. 7 to 40 Nm (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench and various crowfoot wrenches will be needed. Open end or flare nut wrenches will be needed to affix the pipe and hose fittings.
AC-00213
Applicator bottle A small APPLICATOR BOTTLE is recommended to apply compressor oil to the various parts. It can be available at a hardware or drug store.
AC-00012
Manifold gauge set A MANIFOLD GAUGE SET (with hoses) is available either from a refrigerant supplier or an automotive equipment supplier.
AC-00013
AC-18
General Description
ILLUSTRATION Tools and Equipment Refrigerant recovery system A REFRIGERANT RECOVERY SYSTEM is used for the recovery and recycling of A/C system refrigerant after contaminants and moisture have been removed from the refrigerant.
AC-00014
Syringe A graduated plastic SYRINGE will be needed to add oil into the system again. A syringe can be available at a pharmacy or drug store.
AC-00015
Vacuum pump A VACUUM PUMP is necessary (for a good working condition), and is available either at a refrigerant supplier or an automotive equipment supplier.
AC-00016
Can tap A CAN TAP for the 397 g (14 oz.) can is available at an automotive equipment supplier.
AC-00017
Thermometer A Pocket THERMOMETER is available either at a industrial hardware store or a refrigerant supplier.
AC-00018
AC-19
General Description
ILLUSTRATION Tools and Equipment Electronic leak detector An ELECTRONIC LEAK DETECTOR can be available either at a specialty tool supplier or an A/C equipment supplier.
AC-00019
Weight scale A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed, if a 13.6 kg (30 lb) refrigerant container is used.
AC-00020
AC-20
Refrigerant Pressure with Manifold Gauge Set

2. Refrigerant Pressure with Manifold Gauge Set

A: PROCEDURE
1) Place the vehicle in the shade and windless condition. 2) Connect the manifold gauge set. 3) Open the front windows and close all doors. 4) Open the front hood. 5) Increase the engine to 1,500 rpm. 6) Turn on the A/C switch. 7) Turn the temperature control switch to MAX COOL. 8) Put in RECIRC position. 9) Turn the blower control switch to HI. 10) Read the gauge. Standard: Low: 127 196 kPa (1.3 2.0 kg/cm2, 18 28 psi) High: 1,471 1,667 kPa (15 17 kg/cm2, 213 242 psi) Ambient temperature: 30 35C (86 95F)
B: INSPECTION
Symptom Probable cause Defective condenser fan motor Clogged condenser fin Too much refrigerant Air inside the system Defective receiver dryer Repair order Replace the fan motor. Clean the condenser fin. Discharge refrigerant. Replace the receiver dryer. After evacuating again, charge an appropriate amount of refrigerant. Replace the compressor. Check for leaks. Replace the expansion valve. Fully evacuate the expansion valve. Replace the compressor. Replace the expansion valve. Discharge refrigerant. Check for leaks. Replace the expansion valve. Replace the receiver dryer.
High-pressure side is unusually high.
High-pressure side is unusually low.
Low-pressure side is unusually high.
Low-pressure side is unusually low.
Defective compressor Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture. Defective compressor Defective expansion valve Too much refrigerant Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture. Saturated receiver dryer
AC-21
Refrigerant Recovery Procedure

3. Refrigerant Recovery Procedure

A: PROCEDURE
CAUTION: During operation, be sure to wear protective goggles and protective gloves. Connect the refrigerant recovery system with the manifold gauge set to discharge the refrigerant from the A/C system and recycle the gas. When recycling the discharged refrigerant, keep service cans on hand. Because the recovery rate with the recovery system is approx. 90%, service cans are necessary to charge the refrigerant. Follow the detailed operation procedure described in the operation manual attached to the refrigerant recovery system. 1) Perform compressor oil return operation. <Ref. to AC-27, PROCEDURE, Compressor Oil.> 2) Stop the engine. 3) Make sure the valves on low/high pressure sides of manifold gauge set are fully closed.
4) Install the low/high pressure hoses to the service ports on the low/high pressure sides of the vehicle respectively.
(1)
(2)
(3)
AC-00147
(1) Low-pressure side service port (2) High-pressure side service port (3) Close
(3)
(1)
5) Connect the center hose to the refrigerant recovery system. 6) Follow the operation manual to activate the refrigerant recovery system.
(4)
(2)
(5)
(6)
(3) (1) (2) AC-00146
L: H: (1) (2) (3) (4) (5) (6)
Low pressure gauge High-pressure gauge Low pressure valve Vacuum pump valve High pressure valve For low pressure For vacuum pump For high pressure
AC-22
Refrigerant Charging Procedure

4. Refrigerant Charging Procedure

A: PROCEDURE
CAUTION: While working, make sure to wear protective goggles and gloves. Air in the cycle can cause insufficient air conditioning, and water in the cycle can cause clogging in the cycle (icing) and rust. To remove this air and water content, use a vacuum pump to perform evacuation of the system before filling with refrigerant. By making the inside of the cycle a vacuum, the water content will evaporate even at atmospheric temperatures, and can be removed. 1) Close all valves of the manifold gauge.
2) Attach the low pressure side and high pressure side hoses to the vehicle service port. CAUTION: Confirm that the connection is secure.
(1)
(2)
H (3)
(1)
(3) AC-00147
(4)
(2)
(5)
(6)
(1) Low-pressure side service port (2) High-pressure side service port (3) Close
3) Connect the center manifold hose of the manifold gauge to the vacuum pump. 4) Operate the vacuum pump and open the low pressure and high pressure side valves. Next, open the center manifold hose valve, and begin evacuation.
(3) (1) (2) AC-00146
CAUTION: Make sure to perform evacuation using a vacuum pump.
L: H: (1) (2) (3) (4) (5) (6)
Low pressure gauge High-pressure gauge Low pressure valve Vacuum pump valve High pressure valve For low pressure For vacuum pump For high pressure
(2)
(1) AC-00148
(1) Vacuum pump (2) Open
AC-23

5) After performing evacuation for over 5 minutes, when the low pressure gauge needle reaches above 100.0 kPa (750 mmHg, 29.5 inHg), close the center manifold hose valve, and stop the vacuum pump. 6) Leave alone for 5 to 10 minutes after closing the low pressure side and high pressure side valves, and check whether there is any change in the low pressure gauge needle indication. If there is a change, this indicates a leak. Check the pipe and hose connections, and check the location with the problem. In this case, repeat again from step 1). 7) If there is no leakage, continue evacuation for an additional 20 to 30 minutes. 8) Close all valves, and stop the vacuum pump. 9) Follow the can tap operation manual, and attach the refrigerant can.
(1) (2)
13) Loosen the center manifold hose connection on the manifold gauge for a few seconds (if there is a purge valve on the manifold gauge push this instead) to allow the air in the center manifold hose to escape using the refrigerant pressure.
AC-00216
14) Open the high pressure side and low pressure side valves of the manifold gauge to fill with refrigerant. CAUTION: When filling with the engine running, do not open the high pressure side valve. Always fill from the low pressure side.
(1) AC-00214
(1) Tap valve (2) To center manifold hose
(2)
10) Disconnect the center manifold hose from the vacuum pump, and connect the hose to the tap valve. 11) When a 13.6 kg (30 lb) refrigerant container is used, measure the amount of refrigerant with a refrigerant charging scale, and connect with the center manifold hose.
(1)
AC-00217
(1) Open (2) Open
(2)
AC-00215
(1) Refrigerant container (HFC-134a) (2) Weight scale
12) Open the valve on the HFC-134a source.
15) When the gauge needle indicates approximately 200 kPa (1,500 mmHg, 59.1 inHg), close all valves. 16) Using a leak tester, check for refrigerant leaks in the system. 17) After checking that there is no refrigerant leaks, fill with refrigerant up to the specified amount. 18) If the HFC-134a supply container becomes empty, close all valves, and close the can tap valve to replace the empty container. After replacing with a new HFC-134a supply container, perform air purge, and resume the filling operation. 19) If the refrigerant filling efficiency drops, close all valves. 20) Check that both the low pressure and high pressure valves are closed. Start the engine with the A/C switch OFF. 21) To prevent damage to the compressor, push the A/C switch ON-OFF quickly a few times.
AC-24

22) Set up the vehicle to the following status: CAUTION: When filling with the engine running, do not open the high pressure side valve. Always fill from the low pressure side valve. A/C switch ON Engine running at 1,500 rpm Blower speed setting to HI Temperature setting to MAX COOL Air inlet setting to RECIRC Window open 23) Open the low pressure side valve and fill with refrigerant up to the specified amount. 24) After filling with refrigerant, close all valves and disconnect the hose from the service port. 25) Attach the cap of the service port.
AC-25
Refrigerant Leak Check

5. Refrigerant Leak Check

A: INSPECTION
1) Operate the A/C system for approx. 10 minutes, and check that the high-side pressure shows at least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the engine to start the leak test. 2) Starting from the connection between high-pressure pipe and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly. 3) Check the joint and seam between pressure switch (dual switch) and high-pressure pipe. 4) Check the connections between condenser and pipes, and welded joints on the condenser. The leak tester may detect the oil on the condenser fins as a leak. 5) Check the joint between compressor and hoses. 6) Check the machined area of the compressor and other joints on the compressor. 7) Check the compressor shaft seal at the area near the center of compressor clutch pulley. Shaft seals may show a slight amount of leakage, about 3 g (0.1 oz) per year. This is not a problem. 8) Starting from the connection between low-pressure pipe and evaporator, check the system for leakage along the low-pressure side through the compressor. The following items must be checked thoroughly. Connection between 2 parts Connection between pipe and plate
9) Visually check the rubber area of the flexible hose for cracks. Check the entire length of the flexible hose, especially the connection with the metal hose end. CAUTION: Carefully check the external surface of hoses and pipes at approx. 25 mm (0.98 in) per second.
(A)
AC-00036
(A) Flexible hose
10) Disconnect the drain hose from the heater case, and check the hose end for at least 10 seconds. After the test is finished, reconnect the drain hose. 11) Turn the ignition key to the ON position, and run the blower at high speed for approx. 1 minute. Stop the blower and check the ventilation grille on the instrument panel. While moving the tester closer to the grille, run the blower for 1 or 2 seconds, then stop it. Check the grille at that position for at least 10 seconds.
AC-00037 AC-00035
12) Check the valve in the service port. 13) Visually check the rubber seal in the service port cap.
AC-00038
AC-26
Compressor Oil
6. Compressor Oil
A: PROCEDURE
NOTE: Before making repairs, perform the oil return operation to return the compressor oil in circulation with the refrigerant to the compressor. 1) Increase the engine to 1,500 rpm. 2) Turn on the A/C switch. 3) Turn the temperature control switch to MAX COOL. 4) Put in RECIRC position. 5) Turn the blower control switch to HI. 6) Leave in this condition for 10 minutes.
B: REPLACEMENT
NOTE: If a component has been replaced, add an appropriate amount of compressor oil (same as the amount of remaining oil in removed component). When replacing the compressor, the new compressor will already have the specified amount of oil in it. Adjust the oil amount (so that the amount remains the same as that of the removed compressor) and install the new compressor. Since the hygroscopicity of compressor oil is high, perform this series of works quickly.
AC-27
Blower Motor Unit Assembly

7. Blower Motor Unit Assembly

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Remove the glove box. <Ref. to EI-52, REMOVAL, Glove Box.> 3) Disconnect the connectors of the A/C control module, intake door actuator, blower motor, power transistor and blower resistor. 4) Loosen the bolt and nut to remove blower motor unit assembly.
AC-00914
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Refer to COMPONENT of General Description. <Ref. to AC-6, HEATER COOLING UNIT, COMPONENT, General Description.> <Ref. to AC-9, BLOWER MOTOR UNIT, COMPONENT, General Description.>
AC-28
Blower Motor
8. Blower Motor
A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Remove the glove box lower cover. <Ref. to EI52, REMOVAL, Glove Box.> 3) Disconnect the connector of the blower motor. 4) Loosen the screw to remove the blower motor.
AC-00957
B: INSTALLATION
C: INSPECTION
Connect the battery positive (+) terminal to terminal No. 2 of blower motor connector, and negative () terminal to terminal No. 1. Check the blower motor for smooth rotation.
2 1
AC-00915
AC-29
Power Transistor (Auto A/C Model)

9. Power Transistor (Auto A/C Model)

A: REMOVAL
1) Remove the glove box lower cover. <Ref. to EI52, REMOVAL, Glove Box.> 2) Disconnect the power transistor connector. 3) Remove the two screws and remove the power transistor.
AC-00916
B: INSTALLATION
AC-30
Blower Resistor (Manual A/C Model)

10.Blower Resistor (Manual A/C Model)

A: REMOVAL
1) Remove the glove box lower cover. <Ref. to EI52, REMOVAL, Glove Box.> 2) Disconnect the blower resistor connector. 3) Remove the two screws and remove the blower resistor.
AC-00916
B: INSTALLATION
C: INSPECTION
(2) (1)
(4)
(3)
AC-00766
Measure the blower resistor resistance.

Terminal No. 4 and 2 4 and 3 4 and 1 Standard Approx. 0.44 : Approx. 1.12 : Approx. 2.92 :
If NG, replace the blower resistor.
AC-31
Heater Core
11.Heater Core
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to AC-38, REMOVAL, Heater and Cooling Unit.> 2) Remove the screws and remove the heater core cover and pipe clamp.
AC-01133
3) Remove the heater core (A).
(A) AC-01134
B: INSTALLATION
AC-32
Control Panel (Auto A/C Model)

12.Control Panel (Auto A/C Model)

A: REMOVAL
1) Remove the audio assembly. <Ref. to ET-4, REMOVAL, Audio.> 2) Remove the six screws. NOTE: When working with the removed audio assembly with its back facing down, place wooden blocks between the audio assembly and the workbench to prevent the ground terminal from folding.
AC-01553
3) Use a fine flat tip screwdriver to lift the hooks in 10 locations gradually. Starting from the sides, proceed to loosen the lower hooks, then the upper hooks, then remove.
: (A)
AC-01554
(A) Hook
4) Pull the panel straight out to remove. CAUTION: Be careful not to touch the circuit board of the panel to prevent damage by static electricity.
B: INSTALLATION
1) After attaching the hooks, push the center of the panel by hand and secure the connection between the circuit board and the connector. 2) Install in the reverse order of removal.
AC-33
Control Unit (Manual A/C Model)

13.Control Unit (Manual A/C Model)

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Remove the instrument panel lower cover. <Ref. to EI-51, REMOVAL, Instrument Panel Lower Cover.> 3) Remove the control wires.
AC-01597
4) Remove the audio assembly. <Ref. to ET-4, REMOVAL, Audio.> 5) Loosen the screw to remove the control unit from the bracket.
B: INSTALLATION
AC-34
Control Unit (Auto A/C Model)

14.Control Unit (Auto A/C Model)

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Remove the glove box. <Ref. to EI-52, REMOVAL, Glove Box.> 3) Remove the screw, disconnect the connector and remove the control unit.
AC-00919
B: INSTALLATION
AC-35
Compressor
15.Compressor
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
Check the clearance of the entire circumference around the drive plate and pulley. Standard: 0.45r0.15 mm (0.0177r0.0059 in)
8) Disconnect the compressor harness from the body harness. 9) Remove the bolts and remove the compressor bracket. H4 model
2. MAGNETIC CLUTCH OPERATION

1) Disconnect the compressor connector. 2) Connect the battery positive (+) terminal to terminal No. 1 of the compressor connector, and the negative () terminal to terminal No. 2. H6 model
AC-00773
AC-00771
3) Check the magnet clutch engagement. If there is a problem, replace the compressor.
AC-00920
B: REMOVAL
1) Perform compressor oil return operation. <Ref. to AC-27, PROCEDURE, Compressor Oil.> 2) Turn the A/C switch to OFF and stop the engine. 3) Using the refrigerant recovery system, drain the refrigerant. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 4) Disconnect the ground cable from the battery. 5) Remove the V-belts. <Ref. to ME(H4SO)-38, REMOVAL, V-belt.> <Ref. to ME(H4DOTC)-41, REMOVAL, V-belt.> <Ref. to ME(H6DO)-42, REMOVAL, V-belt.> 6) Remove the generator. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 7) Remove the bolt and remove the low-pressure hose and high-pressure hose.
10) Remove the bolts, then remove the bracket from the compressor.
AC-00774
C: INSTALLATION
1) Install in the reverse order of removal. 2) Replace the O-rings on low-/high-pressure hoses with new parts, then apply compressor oil. 3) After replacing the compressor, adjust the amount of compressor oil. <Ref. to AC-27, PROCEDURE, Compressor Oil.> 4) Charge with refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.> Tightening torque: Refer to COMPONENT of General Description. <Ref. to AC-11, AIR CONDITIONING UNIT, COMPONENT, General Description.> <Ref. to AC-12, COMPRESSOR, COMPONENT, General Description.>
AC-00772
AC-36
Condenser
16.Condenser
A: REMOVAL
1) Using the refrigerant recovery system, drain the refrigerant. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 2) Disconnect the ground cable from the battery. 3) Disconnect the pressure hose and pipe from the condenser.
B: INSTALLATION
1) Install in the reverse order of removal. CAUTION: Replace the O-rings on hoses or pipes with new parts, and then apply compressor oil. Confirm that lower guide (A) of condenser fits into holes on radiator panel.
(A) AC-00631 AC-00775
4) Remove the radiator bracket (A) and hood stay (B).

(A) (B) (A)
2) Charge with refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.> Tightening torque: Refer to COMPONENT of General Description. <Ref. to AC-11, AIR CONDITIONING UNIT, COMPONENT, General Description.> <Ref. to CO(H4SO)-4, RADIATOR & RADIATOR FAN, COMPONENT, General Description.>
C: INSPECTION
AC-00776
5) Remove the front grille. <Ref. to EI-24, REMOVAL, Front Grille.> 6) Remove two bolts. While lifting the condenser, pull out through space between the radiator and the radiator panel. CAUTION: Be careful not to damage the condenser fins. If a damaged fin is found, repair it using a thin screwdriver. When replacing the condenser, add an appropriate amount of compressor oil to the compressor. <Ref. to AC-27, REPLACEMENT, Compressor Oil.>
1) Check to see that the condenser fins are not clogged with debris or insects. Blow with compressed air or flush fins with water as needed. 2) Inspect for oil leakage from the condenser. If a failure is found, replace the condenser with a new part.
AC-00777
AC-37
Heater and Cooling Unit

17.Heater and Cooling Unit

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Using the refrigerant recovery system, drain the refrigerant. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 3) Drain engine coolant from the radiator. 4) Remove the bolts securing expansion valve and pipe in engine compartment. Release the heater hose clamps in engine compartment to remove the hoses.
AC-00921
5) Remove the instrument panel. <Ref. to EI-57, REMOVAL, Instrument Panel Assembly.> 6) Remove the support beam. 7) Remove the blower motor unit assembly. <Ref. to AC-28, REMOVAL, Blower Motor Unit Assembly.> 8) Disconnect the actuator connector. 9) Remove the bolt and nuts and remove the heater and cooling unit.
AC-01599
B: INSTALLATION
1) Install in the reverse order of removal. 2) Charge with refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.> Tightening torque: Refer to COMPONENT of General Description. <Ref. to AC-6, HEATER COOLING UNIT, COMPONENT, General Description.>
AC-38
Evaporator
18.Evaporator
A: REMOVAL
1) Using the refrigerant recovery system, drain the refrigerant. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 2) Disconnect the ground cable from the battery. 3) Remove the blower motor unit assembly. <Ref. to AC-28, REMOVAL, Blower Motor Unit Assembly.> 4) Disconnect the connector, remove the screw and then remove the air-mix door actuator and mode door actuator.
7) Remove the bolt which holds the pipe to the evaporator.
AC-00926
8) Remove the screws and clip to remove the evaporator cover.
AC-00923
5) Disconnect the connector, remove the pipe cover and evaporator sensor.
AC-01187
9) Pull out the evaporator (A) in the direction of the arrow. CAUTION: If the evaporator is replaced, add an appropriate amount of compressor oil to evaporator. <Ref. to AC-27, REPLACEMENT, Compressor Oil.>
(A)
AC-00924
6) Remove the bolts securing expansion valve and pipe in engine compartment.
AC-00928
B: INSTALLATION
AC-00925
AC-39
Hose and Pipe

19.Hose and Pipe

A: REMOVAL
CAUTION: When disconnecting hoses and pipes, do not apply excessive force. After installing, check that no torsion or excessive tension applied to the hoses. Seal the disconnected hose with a plug or vinyl tape to prevent foreign matter from entering. 1) Disconnect the ground cable from the battery. 2) Using the refrigerant recovery system, drain the refrigerant. <Ref. to AC-22, PROCEDURE, Refrigerant Recovery Procedure.> 3) Remove the bolt and detach the hoses and pipes.
B: INSTALLATION
CAUTION: Always replace with new O-rings. When connecting hoses and pipes, do not apply excessive force. After installing, check that no torsion or excessive tension applied to the hoses. 1) Install in the reverse order of removal. 2) Charge refrigerant. <Ref. to AC-23, PROCEDURE, Refrigerant Charging Procedure.> Tightening torque: Refer to COMPONENT of General Description. <Ref. to AC-11, AIR CONDITIONING UNIT, COMPONENT, General Description.>
C: INSPECTION
Check the hoses for cracks, damage and expansion. If any fault is found, replace with new parts.
AC-40
Relay and Fuse

20.Relay and Fuse

A: LOCATION
B: INSPECTION
(1) (2) (4)
(3)
(E) (A)
(1)
(2) (B) (D) (C) (3)
(1)
(4)
AC-00641 (2) AC-01570
(3) (4): Continuity exists (1) (2): Continuity does not exist
(1) Joint box (2) Main fuse box Main fan relay 1 Main fan relay 2 Sub fan relay A/C relay A/C Fuse (A) (B) (C) (D) (E)
While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new part.
AC-41
Pressure Switch (Triple Pressure Switch)

21.Pressure Switch (Triple Pressure Switch)

A: INSPECTION
1) Connect the manifold gauge to the service valve on the high-pressure side. 2) Start the air conditioner, and check the operating pressure of switch by turning the compressor (magnet clutch) to ON/OFF. Operation of each switch is as follows.
(10)
(4) (1)
(5) (11)
(10)
(7) (2) (11) (10)
(6)
(9) (3) (11)
(8)
(12) (13) (14) (15) (13)
AC-01433
(1) (2) (3) (4) (5)
High pressure switch Middle pressure switch Low pressure switch 2550r200 kPa (24r2 kg/cm2, 341r28 psi) 3140+50 200 kPa (32.02+0.51 2.04kg/cm2, 455.4+72.5 29.0 psi)
(6) (7)
1770r80 kPa (18.05r0.82 kg/cm2, 256.81r11.6 psi) 1370r120 kPa (13.97r1.22 kg/cm2, 198.65r14.5 psi) 225+25 29 kPa (2.99+0.25 0.3kg/cm2, 3.6+32.6 4.2 psi)
(9) (10) (11) (12) (13) (14) (15)
196r20 kPa (2.0r0.2 kg/cm2, 28.4r2.9 psi) ON OFF Operative range of compressor Inoperative range of compressor Low pressure High pressure
(8)
NOTE: High pressure switch turns the compressor (magnet clutch) to OFF when the refrigerant pressure becomes extremely high to prevent the evaporator, air conditioner piping and expansion valve from getting damaged or frozen. Middle pressure switch effectively controls the radiator fan output by judging height load/low load in normal range. If the refrigerant pressure is abnormally low, the low pressure switch determines that there is insufficient refrigerant, and turns the compressor (magnetic clutch) OFF since there is a possibility that the compressor will seize if it is continued to run.
AC-42
Actuator
22.Actuator
A: REMOVAL
1. MODE DOOR ACTUATOR
Disconnect the connector, remove the screw, and then remove the mode door actuator from the heater and cooling unit.
3. AIR MIX DOOR ACTUATOR (AUTO A/C MODEL)

Disconnect the connector, remove the screw, and then remove the air mix door actuator from the heater and cooling unit. Drivers side
AC-01139 AC-01137
Passengers side
2. INTAKE DOOR ACTUATOR

Disconnect the connector, remove the screw, and then remove the intake door actuator from the blower motor unit.
AC-01140
B: INSTALLATION
AC-01138
AC-43
Ambient Sensor (Auto A/C Model)

23.Ambient Sensor (Auto A/C Model)

A: REMOVAL
1) Open the front hood. 2) Disconnect the ground cable from battery. 3) Disconnect the ambient sensor connector. 4) Remove the ambient sensor from the radiator lower panel.
AC-00125
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-29, AMBIENT SENSOR, Diagnostic Procedure for Sensors.>
AC-44
Sunload Sensor (Auto A/C Model)

24.Sunload Sensor (Auto A/C Model)

A: REMOVAL
1) Disconnect the ground cable from battery. 2) Disconnect the connector and remove the sunload sensor.
AC-00930
CAUTION: Be careful not to damage the interior trims when removing the sensor.
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-35, SUNLOAD SENSOR, Diagnostic Procedure for Sensors.>
AC-45
In-Vehicle Sensor (Auto A/C Model)

25.In-Vehicle Sensor (Auto A/C Model)

A: REMOVAL
1) Disconnect the ground cable from the battery. 2) Remove the console side panel of the drivers side. <Ref. to EI-55, REMOVAL, Center Console.> 3) Disconnect the connector and aspirator hose, remove the claw and remove the in-vehicle sensor from the center console frame. CAUTION: Be careful not to damage the sensors and interior trims when removing.
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-31, IN-VEHICLE SENSOR, Diagnostic Procedure for Sensors.>
AC-46
Air Vent Grille

26.Air Vent Grille

A: REMOVAL
1. CENTER GRILLE
1) Disconnect the ground cable from battery. 2) Remove the three claws and connector to remove center air vent grill.
AC-01555
2. SIDE GRILLE
Remove the catch in 2 locations to remove the side air vent grill.
AC-00932
B: INSTALLATION
C: INSPECTION
1) Check that the direction and amount of air can be adjusted smoothly. 2) Check that the adjustment can be maintained in each position.
AC-47
Heater Duct
27.Heater Duct
A: REMOVAL
1. FRONT HEATER DUCT
1) Remove the instrument panel lower cover. <Ref. to EI-51, REMOVAL, Instrument Panel Lower Cover.> 2) Remove the screws and front heater duct (A).
(A)
AC-00933
2. REAR HEATER DUCT

1) Remove the heater cooling unit. <Ref. to AC-38, REMOVAL, Heater and Cooling Unit.> 2) Remove the front seats. <Ref. to SE-9, REMOVAL, Front Seat.> 3) Remove the front side sill cover. 4) Pull off the floor mat to remove the rear center heater duct (A) and rear heater duct LH, RH (B).
(A)
(B)
AC-00934
B: INSTALLATION
AC-48
Heater Vent Duct

28.Heater Vent Duct

A: REMOVAL
1) Remove the instrument panel. <Ref. to EI-51, REMOVAL, Instrument Panel Lower Cover.> 2) Remove the screws and detach the center vent duct (A). 3) Remove the screws and detach the side vent duct (B). 4) Remove the insulator, remove the screws and detach the defroster duct.
(B) (A) (B) AC-00935
B: INSTALLATION
AC-49
A/C Filter
29.A/C Filter
A: REPLACEMENT
1) Remove the instrument panel side cover.
5) Remove the A/C filter.
AC-01655
6) Install in the reverse order of removal.

PM-00273
2) Remove the clip and the damper (string).
(1)
(2) (1) PM-00274
(1) Clip (2) Damper
3) Remove the upper storage box.
AC-01435
4) Remove the screws, and then remove the cover.
AC-01654
AC-50


A: INSPECTION
Symptoms Repair order Fuse Blower motor relay Blower motor Blower motor resistor (Manual A/C) Blower switch Wiring harness Blower motor Refrigerant Fuses Air conditioning relay Magnet clutch Compressor Pressure switch A/C switch Blower switch Wiring harness V-belt Magnet clutch Compressor Belt tension adjuster Refrigerant V-belt Magnet clutch Compressor Pressure switch Aspirator hose (Auto A/C) Blower fan relay Blower motor A/C switch Blower switch Control module Expansion valve Evaporator Air mix actuator (Auto A/C) Temperature control cable (Manual A/C) Wiring harness Heater duct Heater vent duct Engine coolant Aspirator hose (Auto A/C) Air mix actuator (Auto A/C) Temperature control cable (Manual A/C) Blower switch Heater core
Blower motor
Does not operate.
Strange noise
Does not operate. Compressor
Strange noise
Cold air not emitted.
Warm air not emitted.
AC-51

Symptoms Repair order Engine coolant Air mix actuator (Auto A/C) Temperature control cable (Manual A/C) Temperature control switch (Auto A/C) Wiring harness (Auto A/C) Mode actuator (Auto A/C) Mode switch cable (Manual A/C) Mode switch (Auto A/C) Wiring harness (Auto A/C) FRESH/RECIRC switch (Auto A/C) FRESH/RECIRC actuator (Auto A/C) Wiring harness (Auto A/C)
Temperature of air from vents does not change.
Unable to switch blow vents.
Unable to switch suction vents.
AC-52

HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

A: PROCEDURE
1 Step Check START INSPECTIONS. Does the self-diagnosis oper1) Perform the pre-inspection. <Ref. to ate? AC(diag)-3, INSPECTION, General Description.> 2) Perform the self-diagnosis. <Ref. to AC(diag)-9, OPERATION, Diagnostic Chart for Self-Diagnosis.> IDENTIFY MALFUNCTION PART. Can the malfunction part be Identify the malfunction part with self-diagnosis. confirmed? Yes Go to step 2. No <Ref. to AC(diag)14, A/C OR SELFDIAGNOSIS SYSTEMS DO NOT OPERATE, Diagnostics for A/C System Malfunction.> Go to step 3.
Repair the malfunctioning part in accordance with each diagnostic chart. <Ref. to AC(diag)CHECK COMPARTMENT TEMPERATURE. Does the compartment temper- Go to step 4. ature change? 18, COMPART1) Turn on the A/C switch. 2) Turn the temperature control dial at maxiMENT TEMPERAmum cool position. TURE DOES NOT 3) Check the compartment temperature CHANGE, OR A/C SYSTEM DOES change. NOT RESPOND PROMPTLY, Diagnostics for A/C System Malfunction.> CHECK A/C SYSTEM RESPONSE. Does the A/C system respond A/C system is nor- <Ref. to AC(diag)Change the temperature setting, and check the quickly? mal. 18, COMPARTresponse of A/C system. MENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM DOES NOT RESPOND PROMPTLY, Diagnostics for A/C System Malfunction.>
AC(diag)-2
General Description
A: CAUTION
1) Never connect the battery in reverse polarity. Doing so may immediately damage the auto A/C control module. 2) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as auto A/C control module etc. 3) Before disconnecting the connectors of sensors and the auto A/C control module, be sure to turn off the ignition switch. Auto A/C control module may be damaged. 4) Every A/C-related part is a precision part. Do not drop them. 5) Airbag system wiring harness is routed near the A/C control panel and junction box. CAUTION: Do not use electrical test equipment on wiring harness and connector circuits of the airbag system. Be careful not to damage the airbag system wiring harness when servicing the A/C control panel and junction box.
2. ASPIRATOR HOSE
1) Turn the ignition switch to ON, and press the A/ C switch. 2) Turn the temperature control dial to maximum hot position. 3) Turn the air flow control dial to DEF position. 4) Turn the fan speed control dial to MAX position. 5) Put a strip of paper close to the front side of invehicle sensor suction port (A) located in the drivers side console side panel, and check that air is being sucked into the port by seeing the paper moving towards the port. NOTE: Be careful not to let the paper get sucked into the port.
(A) AC-01188
B: INSPECTION
Before performing the diagnosis, check the following items which may cause problems in the A/C system.
1. BATTERY
1) Measure the battery voltage and specific gravity of electrolyte. Standard voltage: 12 V Specific gravity: 1.260 or more 2) Check the condition of the fuses for A/C system power supply and other fuses. 3) Check the condition of harness and harness connector connections.
6) If the paper does not move at all, remove the drivers side console side panel <Ref. to EI-55, REMOVAL, Center Console.> and check for improper connection of the aspirator hose, in-vehicle sensor and heater unit, and repair them if necessary.
3. A/C LINE
Check the connection for A/C line (A) and lower side high-pressure pipe.
(A)
AC-00895
4. CONTROL LINKAGE
1) Check the state of mode door linkage. 2) Check the state of air mix door linkage. 3) Check the state of FRESH/RECIRC door linkage.
AC(diag)-3
General Description
5. CONTROL SWITCHES
Start the engine and warm up completely. 1) Inspection using switches
No. 1 Point to check OFF switch Switch operation Press the OFF switch. Judgement standard Setting temperature display goes out. Blower fan: OFF Inlet opening: FRESH Compressor: OFF AUTO display illuminates. Outlet air temperature: COOL Blower fan: HI (AUTO) Outlet opening: FACE Inlet opening: AUTO Compressor: AUTO Outlet air temperature: COOL o HOT Blower fan: AUTO Outlet opening: FACE o B/L o FOOT Inlet opening: AUTO Compressor: AUTO Outlet air temperature: HOT Blower fan: HI (AUTO) Outlet opening: FOOT Inlet opening: FRESH (AUTO) Compressor: AUTO Defroster switch indicator illuminates. Outlet air temperature: AUTO Blower fan: AUTO Outlet opening: DEF Inlet opening: FRESH Compressor: ON Inlet opening switches RECIRC o FRESH or FRESH o RECIRC each time pressing the switch. Outlet opening switches FACE o B/L o FOOT o F/D each time pressing the switch. Inlet opening switches LO o M1 o M2 o M3 o M4 o HI each time pressing the switch.
1) Press the AUTO switch. 2) Turn the temperature control dial to the left fully, and set to 18C (65F) (maximum cool position). AUTO switch, drivers side temperature control dial and passengers side temperature control dial
3) Turn the temperature control dial to the right slowly, and change the setting from 18C (65F) (maximum cool position) to 32C (85F).
4) Turn the temperature control dial to the right fully, and set to 32C (85F) (maximum hot position).
Defroster switch
Press the defroster switch.
4 5 6
FRESH/RECIRC switch MODE switch FAN switch
Press the FRESH/RECIRC switch. Press the MODE switch. Press the FAN switch (+).
2) Inspection of compressor operation

No. 1 Point to check Compressor Switch operation 1) Turn the A/C switch to ON. 2) Set the FAN switch between LO and HI. Judgement standard Compressor: ON
3) Inspection of illumination control

No. 1 Point to check Illumination Switch operation Turn the lighting switch to ON. Judgement standard Illumination comes on.
AC(diag)-4


A: LOCATION
1. ENGINE COMPARTMENT
(1) (3) (2)
(4)
AC-00896
(1) (2)
A/C compressor A/C relay
(3)
Pressure switch
(4)
Ambient sensor
(1)
(2)
AC-00813
AC-01603
(4) (3)
AC-00814
AC-00816
AC(diag)-5

2. PASSENGER COMPARTMENT
(9) (8) (7) (6) (5)
(1)
(2)
(3)
(4)
AC-01595
(1) (2) (3)
Evaporator sensor Passengers side air mix door actuator Auto A/C control module
(4) (5) (6)
Blower motor Sunload sensor Intake door actuator
(7) (8) (9)
Mode door actuator In-vehicle sensor Drivers side air mix door actuator
(7) (6)
(2) (1) AC-00898
(3)
(4) AC-00900
(5) (9)
AC-00899
AC-01164
AC(diag)-6
Auto A/C Control Module I/O Signal

4. Auto A/C Control Module I/O Signal

B282
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
AC-01515
Terminal No. Remarks 1 Battery power supply 3 4 5 6 8 9 10 11 12 13 14 15 16 36 17 37 18 38 Air mix door actuator (drivers seat) Air mix door actuator (passengers side) drive signal Mode servo drive signal Mode door actuator position signal Air mix door actuator (passengers side) position signal In-vehicle sensor Sunload sensor Each potentiometer and sunload sensor power supply CAN LO CAN HI Blower motor voltage feedback Blower motor control signal RAM monitor Tx RAM monitor Rx Magnet clutch ON request signal output sensor ground
Measuring condition Ignition switch: OFF Mode door: FACE position Mode door: DEF position Air mix door: Maximum cool position Air mix door: Maximum hot position Ignition switch: ON Ignition switch: ON, With Sunload (No sunload: 0 V) Ignition switch: ON Ignition switch : ON, Blower switch : ON Ignition switch : ON, Blower switch : ON Outputs RAM value when No. 33 (RAMver) terminal is grounded Ignition switch: ON, Blower switch: ON, A/C switch: ON When actuator is operating 16(+) 36(): Turns towards FACE side 16 () 36 (+): rotate to the DEF side 16-36 short: brake When actuator is operating 17(+) 37(): Turns towards COOL side 17 () 37 (+): rotate to the HOT side 17-37 short: brake When actuator is operating 18(+) 38(): Turns towards COOL side 18 () 38 (+): rotate to the HOT side 18-38 short: brake
Standard Battery voltage 4V 1V 4V 1V 25C: 1 5 V 40C: 1 5 V Sunlight: 3 V Room light: 3 V 5V *1 *1 0.45 10 V 9.05 V *1 *1 HI: 5.5 V LO: 2.0 V 0 or 12 V
0 or 12 V
0 or 12 V
AC(diag)-7
Auto A/C Control Module I/O Signal

Terminal No. Remarks 20 Intake door actuator drive signal 40 21 Ignition power supply 22 24 25 26 27 28 32 33 34 35 Pressure switch signal Air mix door actuator (drivers side) position signal Measuring condition When intake door actuator is operating Ignition switch: ON Ignition switch: ON Standard 0.7 V or less Battery voltage Normal: ON Abnormal: OFF 4V 1V 1 4.5 V 0V 0V 0V Battery voltage 0V *1 *1
Air mix door: Maximum cool position Air mix door: Maximum hot position After-evaporator sensor signal Changes by the temperature after the evaporator VER switching signal (FOOT switch) When switching FOOT Sensor ground Always Control module ground Always Heater main relay drive signal Ignition switch: ON RAM monitor ON signal RAM monitor ON Heater control panel communication Heater control panel communication
*1: Battery voltage cannot be measured because of digital signal.
B: WIRING DIAGRAM
1. AIR CONDITIONER AUTO A/C MODEL
<Ref. to WI-111, WIRING DIAGRAM, Air Conditioning System.>
AC(diag)-8
Diagnostic Chart for Self-Diagnosis

5. Diagnostic Chart for Self-Diagnosis

A: OPERATION
(6)
(1)
(8)
(2)
(7)
(5)
(4)
(3)
AC-01536
(1) (2) (3)
Front defroster switch Rear window defogger switch A/C switch
(4) (5) (6)
Air flow control switch FAN switch AUTO switch
(7) (8)
FRESH/RECIRC switch OFF switch
NOTE: For A/C system self-diagnosis, there is one that checks the control panel, and the other that checks the whole control system (sensor, actuator, blower motor, etc.). Perform the self-diagnosis for control panel first, and then perform the self-diagnosis for control system.
AC(diag)-9

1. A/C CONTROL PANEL SELF-DIAGNOSIS

1 Step PERFORM A/C CONTROL PANEL SELF-DIAGNOSIS FUNCTION. 1) Turn the ignition switch to OFF. 2) Turn the ignition switch to ON with the AUTO switch and MODE switch pressed at the same time. 3) All the screen display illuminate (for approx. 5 seconds) and the self-diagnosis mode starts. CHECK SCREEN DISPLAY. Check the illumination condition while the display is illuminated. CHECK SCREEN DISPLAY. After the illumination ends, check the display. Check Does the self-diagnosis function operate? Yes Go to step 2. No <Ref. to AC(diag)14, A/C OR SELFDIAGNOSIS SYSTEMS DO NOT OPERATE, Diagnostics for A/C System Malfunction.> Replace the A/C control panel. Go to step 4.
Does all the screen display and Go to step 3. indicators illuminate?
Are the numbers 11 14 dis- Go to step 5. played at the setting temperature display area? CHECK SWITCH AND TEMPERATURE CON- Does the input of each switch or Go to step 5. TROL DIAL INPUT. dial correspond to the switch 1) Operate each switch or dial according to the check list? switch check table. 2) Check the display or indicator illumination condition when operating the switch or dial. <Ref. to AC(diag)-11, SWITCH CHECK TABLE, OPERATION, Diagnostic Chart for Self-Diagnosis.> CHECK A/C CONTROL PANEL COMMUNI- Is CL displayed on the screen Go to step 6. CATION. when operating each switch 1) Turn the ignition switch to OFF. and dial? 2) Disconnect the connector of the auto A/C control module. 3) Using a suitable lead wire, short the terminal No. 34 and No. 35 of auto A/C control module vehicle side connector (B282). 4) Turn the ignition switch to ON with the A/C switch and AUTO switch pressed at the same time. 5) Check the screen display when operating each switch and dial. CHECK A/C CONTROL PANEL COMMUNI- Is OP displayed on the screen A/C control panel CATION. when operating each switch and body harness 1) Turn the ignition switch to OFF. and dial? are normal. 2) Disconnect the lead wire used to short the terminals. 3) Turn the ignition switch to ON with the A/C switch and AUTO switch pressed at the same time. 4) Check the screen display when operating each switch and dial. CHECK HARNESS. Is the resistance less than 10 :? Go to step 8. 1) Turn the ignition switch to OFF. 2) Disconnect the A/C control panel connector (i88). 3) Measure the resistance between connectors with a tester. Connector & terminal (i88) No. 7 (B282) No. 34: (i88) No. 3 (B282) No. 35:
Replace the heater control panel.
Go to step 7.
Go to step 7.
Repair the open circuit of the harness between A/C control panel and auto A/C control module.
AC(diag)-10

Step CHECK HARNESS. Measure the resistance between connectors with a tester. Connector & terminal (i88) No. 7 No. 3: Check Is the resistance less than 10 :? Yes No Repair the short Replace the A/C circuit of the har- control panel. ness between A/C control panel and auto A/C control module.
2. SWITCH CHECK TABLE
(1)
(2)
(3)
(4)
(5)
(6) (7)
(8)
(10)
(13)
(12)
(9)
(11)
AC-01684
Switch A/C switch AUTO switch Air flow control switch FRESH/RECIRC Defroster switch Rear defogger switch
Display screen (6) (1) (9) (13) (7), (12) (8)
Switch FAN switch (+) FAN switch () Drivers side temperature control dial Passengers side temperature control dial OFF switch
Display screen (4) (3) (9), (10), (12) (9), (11), (12) (2), (5)
AC(diag)-11

3. A/C CONTROL SYSTEM SELF-DIAGNOSIS

1 Step SET SELF-DIAGNOSIS MODE BY OPERATING A/C CONTROL PANEL. 1) Start the engine with the A/C switch and front defroster switch pressed. NOTE: Self-diagnosis can also be performed with ignition switch ON, but start the engine because observing the magnet clutch operation is difficult. 2) All the indicators blink four times. CHECK EACH SENSOR AND POTENTIOMETER. 1) After the indicators stop blinking, automatically change to the Inspection Mode of sensor and potentiometer. NOTE: Display items can be changed each time the A/ C switch is pressed. (Step Operation) 2) When malfunction occurs in each sensor and potentiometer, codes are displayed on the screen. When no malfunction occurs in each sensor and potentiometer, code 20 is displayed on the screen. 3) Identify defective sensors according to the sensor check table. <Ref. to AC(diag)-13, SENSOR CHECK TABLE, OPERATION, Diagnostic Chart for Self-Diagnosis.> CHECK EACH ACTUATOR, BLOWER FAN AND MAGNET CLUTCH. 1) After completing each sensor and potentiometer inspection, change to the Inspection Mode of actuator, blower fan and magnet clutch by pressing the defroster switch. 2) Each mode will change and operate automatically every four seconds. NOTE: Operation mode items can be changed each time the A/C switch is pressed. (Step Operation) 3) Check the operation of actuator, blower fan and magnet clutch in each mode according to the operating mode table. <Ref. to AC(diag)-13, OPERATING MODE TABLE, OPERATION, Diagnostic Chart for Self-Diagnosis.> Check Does the self-diagnosis function operate? Yes Go to step 2. No <Ref. to AC(diag)14, A/C OR SELFDIAGNOSIS SYSTEMS DO NOT OPERATE, Diagnostics for A/C System Malfunction.>
Are other codes except 20 displayed?
Repair the defec- Go to step 3. tive sensor. <Ref. to AC(diag)-29, Diagnostic Procedure for Sensors.>
Do the actuator, blower fan and magnet clutch operate as described in the operating mode table?
A/C control system is normal. Press the OFF switch and complete the self-diagnosis function.
Repair the defective part in accordance with each diagnostic chart. <Ref. to AC(diag)14, Diagnostics for A/C System Malfunction.> or <Ref. to AC(diag)-22, Diagnostic Procedure for Actuators.>
AC(diag)-12

4. SENSOR CHECK TABLE

NOTE: When the sunload sensor check is performed indoors or in the shade, it could be diagnosed as having an open circuit. Always check the sunload sensor with the sun shining on it.
Display screen (Malfunction at present) *1 21/AUTO Blink 21/AUTO Blink 22/AUTO Blink 23/AUTO Blink 23/AUTO Blink 24/AUTO Blink 25 Blink 25/AUTO Blink 26/AUTO Blink 27/AUTO Blink 26/AUTO Blink 27/AUTO Blink 28/AUTO Blink 29/AUTO Blink 20 Blink Sensor In-vehicle sensor Trouble contents
Open Short Ambient sensor Sensor trouble or communication failure Open Evaporator sensor Short Engine coolant temperature sensor Sensor trouble or communication failure Open *2 Sunload sensor Short COOL Drivers side air mix door actuator potentiometer HOT COOL Passengers side air mix door actuator potentiometer HOT FACE Mode door actuator potentiometer DEF When all conditions are normal
*1: AUTO display does not blink when past malfunction occurred. Past malfunction means that abnormal signals were continuously input for a certain time in the past. *2: Present malfunction only is displayed for sunload sensor open circuit.
5. OPERATING MODE TABLE

Display screen 31 32 33 34 35 36 37 38 FRESH/RECIRC door FRESH RECIRC RECIRC FRESH FRESH FRESH FRESH FRESH Mode door FACE FACE FACE B/L FOOT FOOT F/D DEF Air mix door* Maximum cool Maximum cool Maximum cool 50% 50% Maximum hot Maximum hot Maximum hot Blower fan LO LO M1 M1 M1 M3 M3 HI A/C compressor (Magnet clutch) OFF ON ON ON ON ON ON ON
* Same opening angle for both drivers and passengers side
AC(diag)-13
Diagnostics for A/C System Malfunction

6. Diagnostics for A/C System Malfunction

A: A/C OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE
TROUBLE SYMPTOM: Set temperature is not indicated on the display, switch LEDs are faulty and switches do not operate. Self-diagnosis system does not operate. WIRING DIAGRAM:
M/B No. 7
IGNITION SWITCH BATTERY
F/B No. 22
SBF-6
MAIN SBF
1 i88
A/C CONTROL PANEL
i3 10 1 B38
21
35
B282
28
34
B282
B38
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
i88
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
AC-01682
AC(diag)-14

Step CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 7 from main fuse box. 3) Check the condition of fuse. CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 22 from fuse & relay box. 3) Check the condition of fuse. CHECK A/C CONTROL PANEL POWER CIRCUIT. Measure the voltage between A/C control panel harness connector terminal and chassis ground after turning the ignition switch to ON. Connector & terminal (i88) No. 1 (+) Chassis ground (): CHECK A/C CONTROL PANEL GROUND POWER CIRCUIT. Measure the resistance of harness between A/ C control panel and chassis ground after turning the ignition switch to OFF. Connector & terminal (i88) No. 5 Chassis ground: CHECK AUTO A/C CONTROL MODULE POWER CIRCUIT. Measure the voltage between auto A/C control module connector terminal and chassis ground after turning the ignition switch to OFF. Connector & terminal (B282) No. 1 (+) Chassis ground (): CHECK AUTO A/C CONTROL MODULE POWER CIRCUIT. Measure the voltage between auto A/C control module connector terminal and chassis ground after turning the ignition switch to the ON position. Connector & terminal (B282) No. 21 (+) Chassis ground (): CHECK AUTO A/C CONTROL MODULE GROUND CIRCUIT. Measure the resistance of harness between auto A/C control module and chassis ground. Connector & terminal (B282) No. 28 Chassis ground: CHECK COMMUNICATION CIRCUIT. Measure the resistance of harness between A/ C control panel and auto A/C control module. Connector & terminal (i88) No. 3 (B282) No. 35: (i88) No. 7 (B282) No. 34: CHECK POOR CONTACT. Check poor contact of auto A/C control module connector. Check Is the fuse blown out? Yes Replace the fuse. No Go to step 2.
Replace the fuse.
Go to step 3.
Go to step 4.
Check for open or short circuit in the harness between A/C control panel and fuse.
Repair the harness for ground line.
Go to step 6.
Check open or short circuit of harness between auto A/C control module and fuse.
Go to step 7.
Check open or short circuit of harness between auto A/C control module and fuse.
Repair the harness for ground line.
Repair the harness.
Is there poor contact in connec- Repair the connec- Replace the auto tor? tor. A/C control module.
AC(diag)-15

B: BLOWER MOTOR DOES NOT ROTATE

TROUBLE SYMPTOM: Blower motor does not rotate. Blower motor does not rotate in HI. WIRING DIAGRAM:
BATTERY
F/B No. 27
SBF-3
MAIN SBF
F/B No. 28
IGNITION SWITCH
BLOWER MOTOR RELAY
F/B No. 22
SBF-6
21 23 24 22 B225
BLOWER MOTOR
M
POWER TRANSISTOR
2 1 B87
3 2 4 1 B86
B282
11
12
32
B87
B86 1 2 3 4
B225
B282
1 2
1 3 5 7
2 4 6 8
9 10 11 12 25 26 27 28
13 14 15 16 29 30 31 32
17 18 19 20 33 34 35 36
21 22 23 24 37 38 39 40
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
AC-01644
AC(diag)-16

Step CHECK FUSE. 1) Remove fuse No. 22, 27 and 28 from fuse & relay box. 2) Check the condition of fuse. CHECK POWER SUPPLY FOR BLOWER MOTOR. 1) Turn the ignition switch to ON. 2) Turn the blower switch to ON. 3) Measure the voltage between blower motor and chassis ground. Connector & terminal (B87) No. 2 (+) Chassis ground (): CHECK BLOWER MOTOR RELAY. 1) Turn the ignition switch to OFF. 2) Remove the blower motor relay. 3) Connect the battery positive (+) terminal to terminal No. 23 of blower motor relay, and negative () terminal to terminal No. 24. 4) Measure the resistance between terminals No. 21 and No. 22. Terminals (B225) No. 21 (B225) No. 22: CHECK BLOWER MOTOR. 1) Disconnect the connector from blower motor. 2) Connect the battery positive (+) terminal to terminal No. 2 of blower motor connector, and negative () terminal to terminal No. 1. 3) Make sure the blower motor runs. CHECK POOR CONTACT. Check poor contact of auto A/C control module connector. Check Is any fuse blown out? Yes Replace the fuse. No Go to step 2.
Go to step 3.
Repair the open circuit of blower motor power supply line harness.
Replace the blower motor relay.
Does the blower motor run?
Go to step 5.
Replace the blower motor.
AC(diag)-17

C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM DOES NOT RESPOND PROMPTLY
WIRING DIAGRAM:
IGNITION SWITCH BATTERY
F/B No.22
SBF-6
MAIN SBF
C9 14 1 B360
B361
C33 C24 2 4
C: B136
ECM
F109
F108 PRESSURE SWITCH B10 1 3 A/C RELAY F27
14
15
C3
C7
17 MAIN FUSE BOX A: B13 F37 B: B143 C: F35 MAGNET CLUTCH F24 MAIN FUSE BOX A: F37 22 15 B282 AUTO A/C CONTROL MODULE C12 B: B143 C: F35
B20
A13
A4
16
F24 1 2 3
B10 1 4 2
C:
F35
B361 1 2 3 4 5 6 7 8 9 10 11 12 13 14
B282 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
F27
1 2 3 4 5 6 7 8 9 10 11 12
1 F108 5 6 7 8 1 2 3 4 9 10 11 12 13 14 15 16 17 18 F109
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
B360 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A: 1 2 3 4 10 11 12 13 14 F37 5 6 7 8 9 15 16 17 18 19 20
B: B143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 C: B136 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 8 10 11 12 13
3 4 5 6 7 9 14 15 16 17
2 18 19 20 21 22
AC-01683
AC(diag)-18

Step CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 22 from fuse & relay box. 3) Check the condition of fuse. CHECK POWER SUPPLY TO A/C RELAY AND AUTO A/C CONTROL MODULE. 1) Disconnect the A/C relay and auto A/C control module harness connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between A/C relay connector terminal and chassis ground. 4) Measure the voltage between auto A/C control module harness connector terminal and chassis ground. Connector & terminal (F27) No. 17 (+) Chassis ground (): (B282) No. 22 (+) Chassis ground (): CHECK POWER SUPPLY FOR PRESSURE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the pressure switch harness connector. 3) Turn the ignition switch to ON. 4) Measure the voltage between pressure switch harness connector terminal and chassis ground. Connector & terminal (B10) No. 2 (+) Chassis ground (): CHECK HARNESS BETWEEN PRESSURE SWITCH AND A/C RELAY, AUTO A/C CONTROL MODULE. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between pressure switch connector and A/C relay connector. 3) Measure the resistance of harness between pressure switch connector and auto A/C control module connector. Connector & terminal (B10) No. 1 (F27) No. 17: (B10) No. 1 (B282) No. 22: CHECK POWER SUPPLY FOR A/C RELAY. Measure the voltage between A/C relay connector terminal and chassis ground. Connector & terminal (F27) No. 14 (+) Chassis ground (): CHECK A/C RELAY. Check the A/C relay. <Ref. to AC-41, INSPECTION, Relay and Fuse.> Check Is the fuse blown out? Yes Replace the fuse. No Go to step 2.
Go to step 5.
Go to step 3.
Go to step 4.
Check for open or short circuit in the harness between fuse and pressure switch.
Is the resistance less than 1 :? Check the presRepair the harsure switch. <Ref. ness. to AC-42, INSPECTION, Pressure Switch (Triple Pressure Switch).>
Go to step 6.
Check open or short circuit of harness between fuse and A/C relay. Go to step 7.
Is there a malfunction in the A/C Replace the A/C relay? relay.
AC(diag)-19

Step CHECK A/C ON SIGNAL. 1) Turn the ignition switch to OFF. 2) Connect the A/C relay and all disconnected connectors. 3) Start the engine and turn the AUTO switch to ON. 4) Turn the temperature control dial at maximum cool position. 5) Measure the voltage between auto A/C control module harness connector terminal and chassis ground. Connector & terminal (B282) No. 15 (+) Chassis ground (): CHECK HARNESS BETWEEN AUTO A/C CONTROL MODULE AND ECM. 1) Turn the ignition switch to OFF. 2) Disconnect the harness connector of auto A/C control module and ECM. 3) Measure the resistance of harness between auto A/C control module connector and ECM connector. Connector & terminal (B282) No. 15 (B136) No. 24: CHECK MAGNET CLUTCH ON SIGNAL. 1) Stop the engine, and turn the AUTO switch to OFF. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM connector terminal and chassis ground. Connector & terminal (B136) No. 9 (+) Chassis ground (): CHECK MAGNET CLUTCH ON SIGNAL. 1) Start the engine and turn the AUTO switch to ON. 2) Turn the temperature control dial at maximum cool position. 3) Measure the voltage between ECM connector terminal and chassis ground. Connector & terminal (B136) No. 9 (+) Chassis ground (): CHECK POWER SUPPLY FOR MAGNET CLUTCH. 1) Stop the engine, and turn the AUTO switch to OFF. 2) Disconnect the harness connector of magnet clutch. 3) Start the engine and turn the AUTO switch to ON. 4) Turn the temperature control dial at maximum cool position. 5) Measure the voltage between magnet clutch harness connector terminal and chassis ground. Connector & terminal (F24) No. 1 (+) Chassis ground (): Check Is the voltage 5.5 V or more? Yes Go to step 9. No Go to step 8.
Is the resistance less than 1 :? Replace the auto A/C control module.
Repair the harness.
Go to step 10.
Check for open or short circuit in the harness between A/C relay and ECM.
10
Is the voltage 0 V?
Go to step 11.
Replace the ECM.
11
Go to step 12.
Check for open or short circuit in the harness between A/C relay and magnet clutch.
AC(diag)-20

Step Check CHECK HARNESS BETWEEN AUTO A/C Is the resistance less than 1 :? CONTROL MODULE AND ECM. 1) Stop the engine, and turn the AUTO switch to OFF. 2) Measure the resistance between magnet clutch harness connector terminal and chassis ground. Connector & terminal (F24) No. 2 Chassis ground: Yes Inspect the compressor. <Ref. to AC-36, INSPECTION, Compressor.> No Repair the harness.
12
AC(diag)-21
Diagnostic Procedure for Actuators

7. Diagnostic Procedure for Actuators

A: INTAKE DOOR ACTUATOR
TROUBLE SYMPTOM: FRESH/RECIRC mode is not changed. WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
F/B No.22
SBF-6
MAIN SBF
B91 7
1 2 3 4 5 6 7 INTAKE DOOR ACTUATOR
B91
20
40
B282
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
B282
AC-01646
AC(diag)-22

Step CHECK POWER SUPPLY FOR INTAKE DOOR ACTUATOR. 1) Turn the ignition switch to OFF. 2) Disconnect the intake door actuator connector. 3) Turn the ignition switch to ON. 4) Measure the voltage between intake door actuator connector and chassis ground. Connector & terminal (B91) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN AUTO A/C CONTROL MODULE AND INTAKE DOOR ACTUATOR. 1) Turn the ignition switch to OFF. 2) Disconnect the auto A/C control module connector. 3) Measure the resistance between intake door actuator connector and auto A/C control module connector. Connector & terminal (B282) No. 20 (B91) No. 3: (B282) No. 40 (B91) No. 1: CHECK OPERATION OF INTAKE DOOR ACTUATOR. 1) Connect the intake door actuator connector. 2) Ground the auto A/C control module connector with a suitable wire. 3) Turn the ignition switch to ON, and check the operation of intake door actuator. Connector & terminal (B282) No. 20 Chassis ground: CHECK OPERATION OF INTAKE DOOR ACTUATOR. 1) Turn the ignition switch to OFF. 2) Ground the auto A/C control module connector with a suitable wire. 3) Turn the ignition switch to ON, and check the operation of intake door actuator. Connector & terminal (B282) No. 40 Chassis ground: Check Is the voltage 7 V (at normal temperature)? Yes Go to step 2. No Check for open or short circuit in the harness between intake door actuator and fuse.
Repair the harness between auto A/C control module and intake door actuator.
Does the actuator move to the Go to step 4. FRESH side?
Replace the intake door actuator.
Does the actuator move to the Replace the auto RECIRC side? A/C control module.
Replace the intake door actuator.
AC(diag)-23

B: MODE DOOR ACTUATOR

TROUBLE SYMPTOM: Air flow outlet is not changed. WIRING DIAGRAM:
B282 B282
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
36
27
16
B77
1 2 3 4 5 6 7
B77 3 5 6 7 1
MODE DOOR ACTUATOR
AC-01647
AC(diag)-24

Step CHECK POWER SUPPLY FOR MODE DOOR ACTUATOR POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the mode door actuator connector. 3) Turn the ignition switch and AUTO switch to ON. 4) Measure the voltage between auto A/C control module connector terminals. Connector & terminal (B282) No. 8 (+) (B282) No. 27 (): CHECK POWER SUPPLY FOR MODE DOOR ACTUATOR. Measure the voltage between auto A/C control module connector and chassis ground after turning the air flow control switch to FACE position. Connector & terminal (B282) No. 16 (+) Chassis ground (): CHECK POWER SUPPLY FOR MODE DOOR ACTUATOR. Measure the voltage between auto A/C control module connector and chassis ground after turning the air flow control switch to DEF position. Connector & terminal (B282) No. 36 (+) Chassis ground (): CHECK HARNESS BETWEEN AUTO A/C CONTROL MODULE AND MODE DOOR ACTUATOR. 1) Turn the A/C and ignition switch to OFF. 2) Disconnect the auto A/C control module connector. 3) Measure the resistance between auto A/C control module and mode door actuator connector. Connector & terminal (B77) No. 1 (B282) No. 27: (B77) No. 3 (B282) No. 8: (B77) No. 5 (B282) No. 3: (B77) No. 6 (B282) No. 36: (B77) No. 7 (B282) No. 16: CHECK MODE DOOR ACTUATOR POSITION SWITCH SIGNAL. 1) Connect the connector of auto A/C control module and mode door actuator. 2) Turn the ignition switch and AUTO switch to ON. 3) Check the voltage between auto A/C control module connector terminals while changing the mode between DEF and FACE. Connector & terminal (B282) No. 3 (+) (B282) No. 27 (): CHECK POOR CONTACT. Check poor contact of auto A/C control module and connector. Check Is the voltage approx. 5 V? Yes Go to step 2. No Replace the auto A/C control module.
Is the voltage 7 V (at normal temperature)?
Go to step 3.
Replace the auto A/C control module.
Go to step 4.
Repair the harness between auto A/C control module and mode door actuator.
Does the voltage change between 1 V (DEF) and 4 V (FACE)?
Go to step 6.
Replace the mode door actuator.
AC(diag)-25

C: AIR MIX DOOR ACTUATOR

TROUBLE SYMPTOM: Outlet air temperature does not change. WIRING DIAGRAM:
B282
27
38
18
17
B390 5 6 1 5 3 7 1 6 7 3
37
24
B235
DRIVER'S AIR MIX DOOR ACTUATOR
PASSENGER'S AIR MIX DOOR ACTUATOR
B390 B235
B282
1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
AC-01648
AC(diag)-26

Step CHECK POWER SUPPLY FOR AIR MIX DOOR ACTUATOR POSITION SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the air mix door actuator connector. 3) Turn the ignition switch and AUTO switch to ON. 4) Measure the voltage between auto A/C control module connector terminals. Connector & terminal (B282) No. 8 (+) (B282) No. 27 (): CHECK POWER SUPPLY FOR AIR MIX DOOR ACTUATOR. Measure the voltage between auto A/C control module connector and chassis ground after turning the temperature control dial to maximum COOL position. Connector & terminal Drivers side (B282) No. 18 (+) Chassis ground (): Passengers side (B282) No. 17 (+) Chassis ground (): CHECK POWER SUPPLY FOR AIR MIX DOOR ACTUATOR. Measure the voltage between auto A/C control module connector and chassis ground after turning the temperature control dial to maximum HOT position. Connector & terminal Drivers side (B282) No. 38 (+) Chassis ground (): Passengers side (B282) No. 37 (+) Chassis ground (): CHECK HARNESS BETWEEN AUTO A/C CONTROL MODULE AND AIR MIX DOOR ACTUATOR. 1) Turn the A/C and ignition switch to OFF. 2) Disconnect the auto A/C control module connector. 3) Measure the resistance between auto A/C control module and air mix door actuator connector. Connector & terminal Drivers side (B390) No. 1 (B282) No. 27: (B390) No. 3 (B282) No. 8: (B390) No. 5 (B282) No. 24: (B390) No. 6 (B282) No. 38: (B390) No. 7 (B282) No. 18: Passengers side (B235) No. 1 (B282) No. 8: (B235) No. 3 (B282) No. 27: (B235) No. 5 (B282) No. 4: (B235) No. 6 (B282) No. 17: (B235) No. 7 (B282) No. 37: Check Is the voltage approx. 5 V? Yes Go to step 2. No Replace the auto A/C control module.
Go to step 3.
Go to step 4.
Repair the harness between auto A/C control module and air mix door actuator.
AC(diag)-27

Step CHECK AIR MIX DOOR ACTUATOR POSITION SWITCH SIGNAL. 1) Connect the connector of auto A/C control module and air mix door actuator. 2) Turn the ignition switch and AUTO switch to ON. 3) Check the voltage between auto A/C control module connector terminals while changing the setting temperature between maximum COOL and maximum HOT. Connector & terminal Drivers side (B282) No. 24 (+) (B282) No. 27 (): Passengers side (B282) No. 4 (+) (B282) No. 27 (): CHECK POOR CONTACT. Check poor contact of auto A/C control module and connector. Check Yes Go to step 6. Does the voltage change between 1 V (Max. HOT) and 4 V (Max. COOL)? No Replace the air mix door actuator.
AC(diag)-28
Diagnostic Procedure for Sensors

8. Diagnostic Procedure for Sensors

A: AMBIENT SENSOR
TROUBLE SYMPTOM: Fan speed is not switched when the fan speed control dial is in AUTO position. WIRING DIAGRAM:
AMBIENT SENSOR
1 13 11 C10 B25 9
F78
14
F108 THROUGH JOINT CONNECTOR
10
B361
C3
C: B281
BODY INTEGRATED UNIT B26
B: B280
B282
10
F78 1 2
F108
B361
B: B280
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
C: B281 B282
4 5 6 7 1 2 3 8 9 10 11 12 13 14 15 16 17 18 19 27 28 24 25 26 22 23 20 21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
AC-01652
AC(diag)-29

Step CHECK AMBIENT SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ambient sensor. 3) Measure the resistance between connector terminals of ambient sensor. Terminals No. 1 No. 2: CHECK INPUT SIGNAL FOR AMBIENT SENSOR. 1) Turn the ignition to ON. 2) Measure the voltage between connector (F78) terminals. Connector & terminal (F78) No. 2 (+) No. 1 (): CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Turn the ignition switch to OFF. 2) Draw out the body integrated unit. 3) Disconnect the connector from ambient sensor. 4) Turn the ignition switch to ON. 5) Measure the voltage between connector terminals of body integrated unit. Connector & terminal (B281) No. 3 (+) No. 10 (): CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND AMBIENT SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from body integrated unit. 3) Measure the resistance of harness between body integrated unit and ambient sensor. Connector & terminal (F78) No. 1 (B281) No. 10: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND AMBIENT SENSOR. Measure the resistance of harness between body integrated unit and ambient sensor. Connector & terminal (F78) No. 2 (B281) No. 3: CHECK DTC. 1) Connect the connectors of body integrated unit and ambient sensor as originally connected. 2) Read the DTC of body integrated unit using Subaru Select Monitor. CHECK POOR CONTACT. Check poor contact of auto A/C control module connector. Check Yes Is the resistance approximately Go to step 2. 2.2 k: at 25C (77F) ? No Replace the ambient sensor.
Is the voltage approx. 5 V?
Go to step 6.
Go to step 3.
Go to step 4.
Go to step 6.
Repair the open circuit of harness between body integrated unit and ambient sensor.
Repair the open circuit of harness between body integrated unit and ambient sensor.
Is DTC U xxx of CAN commu- Check the commu- Go to step 7. nication displayed? nication circuit. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.> Is there poor contact in connec- Repair the connec- Replace the auto tor? tor. A/C control module.
AC(diag)-30

B: IN-VEHICLE SENSOR
TROUBLE SYMPTOM: Blower fan speed, outlet port and inlet port do not change after turning the AUTO switch to ON. WIRING DIAGRAM:
i55
IN-VEHICLE SENSOR
i3 11 12 B38 B282 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 5
B282 AUTO A/C CONTROL MODULE
i55
27
B38
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AC-01649
AC(diag)-31

Step CHECK IN-VEHICLE SENSOR. 1) Turn the ignition switch to OFF. 2) Remove the drivers side lower cover. 3) Disconnect the connector from in-vehicle sensor. 4) Measure the resistance between connector terminals of in-vehicle sensor. Terminals No. 1 No. 2: CHECK INPUT SIGNAL FOR IN-VEHICLE SENSOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between in-vehicle sensor harness connector terminal and chassis ground. Connector & terminal (i55) No. 2 (+) No. 1 (): CHECK AUTO A/C CONTROL MODULE OUTPUT SIGNAL. 1) Turn the ignition switch to OFF. 2) Remove the auto A/C control module. 3) Turn the ignition switch to ON. 4) Measure the voltage between connector terminals of auto A/C control module. Connector & terminal (B282) No. 5 (+) (B282) No. 27 (): CHECK HARNESS BETWEEN AUTO A/C CONTROL MODULE AND IN-VEHICLE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the auto A/C control module. 3) Measure the resistance of harness between auto A/C control module and in-vehicle sensor. Connector & terminal (i55) No. 2 (B282) No. 5: CHECK HARNESS BETWEEN AUTO A/C CONTROL MODULE AND IN-VEHICLE SENSOR. Measure the resistance of harness between auto A/C control module and in-vehicle sensor. Connector & terminal (i55) No. 1 (B282) No. 27: CHECK POOR CONTACT. Check poor contact of auto A/C control module connector. Check Yes Is the resistance approximately Go to step 2. 2.7 k: at 20C (68F) ? No Replace the invehicle sensor.
Go to step 6.
Go to step 3.
Go to step 4.
Go to step 6.
Repair the harness between auto A/C control module and in-vehicle sensor.
Repair the harness between auto A/C control module and in-vehicle sensor.
AC(diag)-32

C: EVAPORATOR SENSOR
WIRING DIAGRAM:
EVAPORATOR SENSOR
B88
2 B282
27
25
B282
B88
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
AC-01650
AC(diag)-33

Step CHECK EVAPORATOR SENSOR. 1) Turn the ignition switch to OFF. 2) Remove the glove box. 3) Disconnect the connector from evaporator sensor. 4) Measure the resistance between connector terminals of the evaporator sensor. Terminals No. 1 No. 2: CHECK INPUT SIGNAL FOR EVAPORATOR SENSOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between connector (B88) terminal and chassis ground. Connector & terminal (B88) No. 1 (+) No. 2 (): CHECK AUTO A/C CONTROL MODULE OUTPUT SIGNAL. 1) Turn the ignition switch to OFF. 2) Remove the auto A/C control module. 3) Turn the ignition switch to ON. 4) Measure the voltage between connector terminals of auto A/C control module. Connector & terminal (B282) No. 25 (+) No. 27 (): CHECK HARNESS CONNECTOR BETWEEN AUTO A/C CONTROL MODULE AND EVAPORATOR SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the auto A/C control module. 3) Measure the resistance of harness between auto A/C control module and evaporator sensor. Connector & terminal (B88) No. 2 (B282) No. 27: CHECK HARNESS CONNECTOR BETWEEN AUTO A/C CONTROL MODULE AND EVAPORATOR SENSOR. Measure the resistance of harness between auto A/C control module and evaporator sensor. Connector & terminal (B88) No. 1 (B282) No. 25: CHECK POOR CONTACT. Check poor contact of auto A/C control module connector. Check Yes Is the resistance approximately Go to step 2. 3.3 k: at 20C (68F) ? No Replace the evaporator sensor.
Go to step 6.
Go to step 3.
Go to step 4.
Go to step 6.
Repair the open circuit of harness between auto A/C control module and evaporator sensor.
Repair the open circuit of harness between auto A/C control module and evaporator sensor.
AC(diag)-34

D: SUNLOAD SENSOR
TROUBLE SYMPTOM: Sensor identifies that sunlight is at maximum. Then, A/C system is controlled to COOL side. Sensor identifies that sunlight is at minimum. Then, A/C system is controlled to HOT side. NOTE: When the sunload sensor check is performed indoors or in the shade, it could be diagnosed as having an open circuit. Always check the sunload sensor with the sun shining on it. WIRING DIAGRAM:
i51
SUNLOAD SENSOR
i3 2 3 B38
B282
i51
B282 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
B38
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AC-01651
AC(diag)-35

Step CHECK POWER SUPPLY VOLTAGE FOR SUNLOAD SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from sunload sensor. 3) Turn the ignition switch to ON. 4) Measure the power supply voltage for sunload sensor. Connector & terminal (i51) No. 1 (+) No. 2 (): CHECK HARNESS CONNECTOR BETWEEN AUTO A/C CONTROL MODULE AND SUNLOAD SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the auto A/C control module. 3) Measure the resistance of the harness between the auto A/C control module and sunload sensor. Connector & terminal (i51) No. 2 (B282) No. 6: CHECK HARNESS CONNECTOR BETWEEN AUTO A/C CONTROL MODULE AND SUNLOAD SENSOR. Measure the resistance of the harness between the auto A/C control module and sunload sensor. Connector & terminal (i51) No. 1 (B282) No. 8: CHECK INPUT VOLTAGE FOR AUTO A/C CONTROL MODULE. 1) Connect the connectors of sunload sensor and auto A/C control module. 2) Turn the ignition switch to ON. 3) Measure the voltage between connector terminals of auto A/C control module. Connector & terminal (B282) No. 8 (+) (B282) No. 6 (): CHECK POOR CONTACT. Check poor contact of auto A/C control module connector. Check Is the voltage approx. 5 V? Yes Go to step 4. No Go to step 2.
Repair the harness between auto A/C control module and sunload sensor.
Repair the harness between auto A/C control module and sunload sensor.
Is the voltage approx. 2.5 V?
Go to step 5.
Replace the sunload sensor.
AC(diag)-36

E: A/C LOCK SENSOR

H6 model WIRING DIAGRAM:
A/C LOCK SENSOR 1 A18 F115 2 A16
A20 B10
B14
B12
MAIN FUSE BOX (M/B)
A: F37
B: B143
B: B135 C: B136 ECM
B14
C24
TERMINAL No. : OPTIONAL ARRANGEMENT
JOINT CONNECTOR B83
* * * *
15
B282
F115
B83
B122
A: F37
B: B143
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B282
1 2
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B: B135
C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32 5 6 14 15 16 25 26 27 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
AC-01653
AC(diag)-37

Step CHECK A/C LOCK SENSOR SIGNAL. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Start the engine and turn the A/C switch to ON. 4) Read the data of A/C lock signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to READ CURRENT DATA FOR ENGINE. <Ref. to EN(H6DO)(diag)-35, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> CHECK A/C LOCK SENSOR SIGNAL. 1) Start the engine and turn the A/C switch to ON. 2) Measure the voltage between auto A/C control module connector and chassis ground. Connector & terminal (B282) No. 15 (+) Chassis ground (): CHECK ECM OUTPUT. Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 24 (+) Chassis ground (): CHECK A/C LOCK SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connector and chassis ground. Connector & terminal (B135) No. 14 Chassis ground: CHECK A/C LOCK SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the main fuse box connector. 3) Measure the resistance between main fuse box terminal. Connector & terminal (F37) No. 16 No. 18: CHECK A/C LOCK SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the A/C lock sensor connector. 3) Measure the resistance between A/C lock sensor terminals. Connector & terminal (F115) No. 1 No. 2: CHECK MAIN FUSE BOX. 1) Turn the ignition switch to OFF. 2) Disconnect the connector and then measure the resistance between main fuse box terminal. Connector & terminal (F37) No. 16 (B143) No. 14: (F37) No. 18 (B143) No. 12: Check Is the A/C lock signal switch ON? Yes Go to step 4. No Go to step 2.
Go to step 3.
Repair the harness Replace the ECM. between ECM and auto A/C control module. Replace the ECM. Go to step 5.
Go to step 7.
Go to step 6.
Repair or replace the harness between A/C lock sensor and main fuse box.
Replace the A/C compressor assembly. (A/C lock switch malfunction)
Is the resistance less than 10 :? Repair or replace the harness between A/C lock sensor and main fuse box.
Replace the main fuse box.
AC(diag)-38
Diagnostics with Phenomenon

9. Diagnostics with Phenomenon

A: INSPECTION
Symptom Problem parts Fuse (M/B No. 8, F/B No. 22, 31) Connector (Poor contact) Ground Auto A/C control module Blower fan motor Blower fan relay A/C relay Compressor (Magnet clutch) Evaporator sensor Fuse (M/B No. 8, F/B No. 22, 31) Connector (Poor contact) Fuse (M/B No. 8, F/B No. 22, 31) Connector (Poor contact) Auto A/C control module Body integrated unit Fuse (F/B No. 22, 27, 28) Connector (Poor contact) Ground Auto A/C control module Blower fan motor Blower fan relay Connector (Poor contact) Auto A/C control module Intake door actuator
A/C system fails to operate.
Fuse is blown out.
Illumination cannot dim.
Blower fan does not rotate or fan speed cannot be controlled.
Unable to switch suction vents.
Unable to switch vents.
The compartment temperature does not rise. (Warm air does not come out.)
The compartment temperature does not lower. (Cold air does not come out.)
Compartment temperature is higher or lower than setting temperature.
Compartment temperature does not quickly respond to setting temperature. Radiator fan does not rotate during A/C operation.
Connector (Poor contact) Auto A/C control module Mode door actuator Connector (Poor contact) Auto A/C control module Air mix door actuator In-vehicle sensor, ambient sensor, evaporator sensor and sunload sensor In-vehicle sensor aspirator hose Connector (Poor contact) Auto A/C control module Air mix door actuator A/C relay Compressor (Magnet clutch) Radiator fan motor Radiator fan relay In-vehicle sensor, ambient sensor, evaporator sensor and sunload sensor In-vehicle sensor aspirator hose Auto A/C control module Air mix door actuator In-vehicle sensor, ambient sensor, evaporator sensor and sunload sensor In-vehicle sensor aspirator hose Air mix door actuator In-vehicle sensor, ambient sensor, evaporator sensor and sunload sensor In-vehicle sensor aspirator hose Radiator fan motor Radiator fan relay
AC(diag)-39
Diagnostics with Phenomenon

AC(diag)-40
General Description
AIRBAG SYSTEM
A: COMPONENT
1. DRIVERS AIRBAG MODULE
4. AIRBAG CONTROL MODULE

T
)A(
T T T T
AB-01251
(A) Bolt
AB-01617
CAUTION: Do not reuse mounting bolts and nuts. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
2. PASSENGERS AIRBAG MODULE
5. FRONT SUB SENSOR
(A)
T T AB-00753 (A)
AB-01189
(A) Bolt
3. SIDE AIRBAG MODULE

T
CAUTION: Do not reuse mounting bolts and nuts. Tightening torque: 13 Nm (1.32 kgf-m, 9.6 ft-lb)
AB-00754
AB-2
General Description
AIRBAG SYSTEM
6. SIDE AIRBAG SENSOR
8. SATELLITE SAFING SENSOR

T (A)
(A)
AB-02029
AB-02135
(A) Nut
(A) Bolt
CAUTION: Do not reuse mounting bolts and nuts. Tightening torque: 8.0 Nm (0.82 kgf-m, 5.9 ft-lb)
7. CURTAIN AIRBAG SENSOR
9. STEERING ROLL CONNECTOR
(A)
AB-01748
AB-00756
(A) Nut
10.CURTAIN AIRBAG MODULE

Sedan model
(3) (3)
(A) (F) (3) (3)
(B) : (1) : (2) AB-01618
AB-3
General Description
AIRBAG SYSTEM
Wagon model
(3) (3)
(A) (F) (3) (3)
If the airbag warning light illuminates, repair the vehicle immediately. Otherwise, the airbag or pretensioner may inflate incorrectly, or not inflate in collision. If sensors, airbag module, airbag control module, pretensioner, harness or satellite safing sensor cover is deformed or damaged, replace with new part.
(B) : (1) : (2) AB-01619
(A) (B) (F)
Model with sunroof Model without sunroof Front side of vehicle
(1) (2) (3)
Bolt Clip Plate guard
NG N G
AB-01534
11.AIRBAG HARNESS
When checking the airbag system, be sure to use a digital circuit tester. Use of an analog circuit tester may cause the airbag to activate erroneously due to a minimal current inside tester.
(1)
(2) AB-01750
OK K NG N G O
AB-01535
(1) Airbag main harness (2) Airbag rear harness
B: CAUTION
When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for 20 seconds or more before starting work. The airbag system is fitted with a backup power source. After disconnecting the battery ground cable, the airbag may deploy if you do not wait for 20 seconds or more before starting airbag system servicing.
IN-00203
AB-4
General Description
AIRBAG SYSTEM
When checking, use a test harness (1). Damage to connector terminal causes malfunction. Do not directly apply the tester probe to connector terminal of airbag.
If damage, open circuit or rust is found on airbag system wiring harness, do not use a soldering equipment to repair. Replace the faulty harness with a new genuine part.
NG N G OK O K
(1) AB-01536
NG N G
AB-01539
Install the wiring harness securely with the specified clips to avoid interference or tangled with other parts.
Do not allow water or oil to come in contact with the connector terminals. Also, do not touch the connector terminals.
AB-00125
NG N G
AB-01540
When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender and front side frame, remove the front sub sensors and wiring harness of airbag system. When painting or performing sheet metal work on the side of the vehicle or floor pan, around rear crossmember, including the side sill, center pillar and front and rear doors, remove the side airbag sensors, curtain airbag sensor, satellite safing sensor and wiring harness of the airbag system.
Do not check continuity of the airbag modules for drivers side, passengers side and curtain, or the pretensioner.
NG NG
AB-01537
NG N G
AB-01542
Do not use the airbag or pretensioner parts from other vehicles. Always replace the defective parts with new parts. Never reuse a deployed airbag module and pretensioner.
AB-5
General Description
AIRBAG SYSTEM
Do not discard the uninflated airbag or pretensioner. When airbag control module, front sub sensor, side airbag sensor and curtain airbag sensor or satellite safing sensor are removed, do not reuse the bolts and nuts of them. Always use new bolts and nuts for them. Do not drop each airbag module, airbag control module and each sensor, or store these parts under high temperature of 85C (185F) or more, or let water, oil or grease get on them; the internal parts may be damaged or the reliability may be greatly lowered.
Do not disassemble drivers airbag module, passengers airbag module, side or curtain airbag modules, or pretensioner.
NG NG
(1)
AB-01541
When performing attachment of the steering wheel and steering roll connector, make sure to perform adjustment of the steering roll connector. The removed front seat with airbag module must be kept at least 200 mm (8 in) away from walls and other objects.
NG NG
AB-01538
AB-00128
(1) 200 mm (8 in) or more
After removal of each parts for airbag system, keep them with the pad facing upward on a dry, clean and flat surface without heat, light sources, moisture and dust.
AB-00056
AB-6
General Description
AIRBAG SYSTEM
When storing a removed airbag module, do not place with its pad side facing down. Do not place any objects on the airbag module. Do not pile up the airbag module. If the airbag inflates for some reason when an airbag module pad is touching other objects, it may cause serious accident.
(1)
OK
NG NG
(2)
OK
NG NG
AB-01543
(1)
Drivers airbag module
(2)
Passengers airbag module
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME TORX T30
REMARKS Used for removing and installing drivers airbag module.
AB-7
Airbag Connector
AIRBAG SYSTEM
2. Airbag Connector
A: PROCEDURE
1) How to disconnect: Press the lock lever plate (A) and pull out the lock lever.
(2) Pull the connector to disconnect from the drivers airbag module assembly or the retractor assembly.
(A)
AB-00479
AB-01751
2) How to connect: Connect the connector in the reverse order of disconnecting. At this time, be sure to insert the push lock until a clicking sound is heard. CAUTION: Be sure to insert the connector in until it is locked. Then pull it lightly to make sure that it is locked. Be sure to push the push lock in securely.
2) How to connect: Insert the connector, push the lock lever in securely. CAUTION: Be sure to insert the connector in until it is locked. Then pull it lightly to make sure that it is locked.
2. DRIVERS AIRBAG MODULE, PRETENSIONER AND CURTAIN AIRBAG MODULE

1) How to disconnect: (1) Using a flat tip screwdriver, pry the push lock upward to unlock.
AB-00480
NOTE: The connector cannot be connected when the push lock is in the lock position. Move the push lock to the release position and connect the connector.
AB-00478
AB-8
Airbag Connector
AIRBAG SYSTEM
3. DRIVERS AIRBAG (BETWEEN AIRBAG MAIN HARNESS AND ROLL CONNECTOR) AND SIDE AIRBAG
1) How to disconnect: (1) Push the slide lock (A) in the direction of arrow.
4. SIDE AIRBAG
1) How to disconnect: (1) Push the lock arm (A). (2) With the lock arm (A) pushed in, move the slide lock (B) in the direction of arrow.
(B)
(A)
(A)
AB-00017 AB-00722
(2) With the slide lock pushed, disconnect the connector. CAUTION: When pulling the slide lock or disconnecting connector, be sure to hold the connector, not the harness.
(3) With the slide lock moved, release the lock arm (return to original position) and disconnect the connector. CAUTION: When pulling the slide lock or disconnecting connector, be sure to hold the connector, not the harness.
AB-00022
AB-00018
2) How to connect: Holding the connector, push it in securely until a clicking sound is heard. CAUTION: Be sure to insert the connector in until it is locked. Then pull it gently to make sure that it is locked.
2) How to connect: Holding the connector, push it in securely until a clicking sound is heard. CAUTION: Be sure to insert the connector in until it is locked. Then pull it lightly to make sure that it is locked.
AB-00023
AB-00019
AB-9
Airbag Connector
AIRBAG SYSTEM
5. FRONT SUB SENSOR, SIDE AIRBAG SENSOR, CURTAIN AIRBAG SENSOR AND SATELLITE SAFING SENSOR
1) How to disconnect: Holding outer part (A), pull it in the direction of arrow. CAUTION: When pulling the slide lock or disconnecting connector, be sure to hold the connector, not the harness.
6. PASSENGER DETECTION SYSTEM (BETWEEN AIRBAG REAR HARNESS AND SEAT HARNESS) AND BELT TENSION SENSOR
1) How to disconnect: Push lock arm (A), then disconnect the connector. CAUTION: When pulling the slide lock or disconnecting connector, be sure to hold the connector, not the harness.
(A)
AB-00024
AB-01325
2) How to connect: Holding the connector, push it in securely until a clicking sound is heard. CAUTION: Do not touch the outer side section or else the outer side (A) will move back. Be sure to insert the connector in until it is locked. Then pull it lightly to make sure that it is locked.
2) How to connect: Holding the connector, push it in securely until a clicking sound is heard. CAUTION: Be sure to insert the connector in until it is locked. Then pull it lightly to make sure that it is locked.
AB-00025
AB-10
Inspection Locations After a Collision

AIRBAG SYSTEM
3. Inspection Locations After a Collision

A: REPLACEMENT
Replace the following parts when the airbag is deployed.
1. FRONT COLLISION
1) Drivers airbag module 2) Passengers airbag module 3) Drivers seat belt (Pretensioner) 4) Passengers seat belt (Pretensioner) 5) Airbag control module 6) Front sub sensor (L/R) 7) Roll connector 8) Instrument panel (for integrating with passengers airbag module) 9) Passengers side seat cushion pad and frame assembly
5) If there are tears or loosening in the passenger side seat cushion cover, it may interfere with the proper operation of the occupant detection system. Replace with a new cushion cover. 6) Be sure to perform the system calibration for the occupant detection system after removing or replacing the passenger seat cushion cover. Failure to do so may cause improper operation of the occupant detection system. <Ref. to OD(diag)-15, SYSTEM CALIBRATION (REZEROING), OPERATION, Subaru Select Monitor.> 7) Use the Subaru Select Monitor to check whether the passengers seat belt buckle switch is operating normally.
B: INSPECTION
If the vehicle is involved in a collision, even if it is a slight collision, be sure to check the following systems.
1. DRIVERS AIRBAG MODULE

1) Check for the following, and replace the damaged parts with new parts. Airbag module is cracked or deformed. Harness and/or connector is cracked, deformed or open. Harness wire is exposed. The module surface is fouled with grease, oil, water or cleaning solvent. 2) When installing a new drivers airbag module, check for the following, and replace the damaged parts with new parts. The steering wheel is in the way, making it difficult to install the airbag module. The clearance between the drivers airbag module and steering wheel is not constant. When steering wheel deformation in axial and vertical directions exceed limits. Specification: Axial deflection A Less than 6 mm (0.24 in) Vertical deflection L Less than 15 mm (0.59 in)
L A
2. SIDE COLLISION
1) Airbag control module 2) Satellite safing sensor 3) Side airbag module (operating side seat backrest) 4) Side airbag sensor (operating side) 5) Curtain airbag module (operating side) 6) Curtain airbag sensor (operating side) 7) Satellite safing sensor mounting bracket and cover
3. INSPECTION OF OTHER PARTS

Check for the following parts, and replace the damaged parts with new parts. 1) Steering wheel and steering shaft Check the steering shaft for mounting conditions and deflection of front and rear, upward and downward directions, and deflection of front and rear direction with tilt lever released. (After a collision, absorbing part of steering shaft may have been operated.) 2) Check the direct type connector of drivers airbag module, curtain airbag module and pretensioner, etc. for damage, and also check each harness for pinch and connector damage. Replace the harness as a unit if damage is found. 3) Check the seat cushion frame, backrest, slide rail and headrest for deformation, distortion, crack, and installing condition and play. 4) For the passengers seat, replace the seat cushion pad and frame assembly with a new part if the seat cushion pad and frame assembly is deformed or cracked.
AB-00028
AB-11

AIRBAG SYSTEM
2. PASSENGERS AIRBAG MODULE

Check for the following, and replace the damaged parts with new parts. Airbag module and instrument panel are cracked or deformed. Harness and/or connector is cracked, deformed or open. Harness wire is exposed. Mounting bracket is cracked or deformed.
7. SATELLITE SAFING SENSOR, SIDE AIRBAG SENSOR AND CURTAIN AIRBAG SENSOR
If the section of vehicle as shown in the figure is damaged, check the following items and replace the damaged parts with new parts.
3. SIDE AIRBAG MODULE

Check for the following, and replace the damaged parts with new parts. Front seat, airbag module and mounting bracket are damaged or deformed. Harness and/or connector is cracked, deformed or open. Harness wire is exposed.
4. CURTAIN AIRBAG MODULE

Check for the following, and replace the damaged parts with new parts. Airbag cover is scratched or torn. Harness and/or connector is cracked, deformed or open. Harness wire is exposed. Mounting bracket and securing clip are cracked or deformed.
AB-01869
Satellite safing sensor, side airbag sensor and curtain airbag sensor are cracked or deformed. Mounting bracket is cracked or deformed. Satellite safing sensor is cracked or deformed. Connector is scratched, cracked or deformed. Side airbag or curtain airbag is deployed. (operating side)

Check for the following, and replace the damaged parts with new parts. Control module is cracked or deformed. Mounting bracket is cracked or deformed. Connector is scratched, cracked or deformed. Airbag is deployed. Side airbag is deployed. Curtain airbag is deployed.
8. ROLL CONNECTOR
Check for the following, and replace the damaged parts with new parts. Combination switch or steering roll connector is cracked or deformed.
9. STEERING SHAFT
Check for the following, and replace the damaged parts with new parts. Overall length of steering column should be within specification. Specification: Overall length L Tilt and telescopic column (measure while minimized) Except for OUTBACK model 818.6+1.5 1.5 mm (32.23+0.059 0.059 in) OUTBACK model 810.4+1.5 1.5 mm (31.89+0.059 0.059 in)
6. FRONT SUB SENSOR

If the section of vehicle as shown in the figure is damaged, check the following items and replace the damaged parts with new parts.
AB-00029
Front sub sensor is cracked or deformed. Connector is scratched, cracked or deformed. Airbag is deployed.
AB-00728
AB-12

AIRBAG SYSTEM
10.DRIVERS SEAT
Check for the following, and replace the damaged parts with new parts. Seat belt buckle body/bracket is cracked or deformed. Harness and/or connector is cracked, deformed or open. Harness wire is exposed.
11.PASSENGERS SEAT
1) Check for the following, and replace the damaged parts with new parts. Seat belt buckle body, bracket or connector is scratched, cracked or deformed. Backrest frame for crack or deformation Headrest for deformation or play If the seat cushion cover and seat backrest cover is scratched or coming loose, replace with a new cover and readjust the system. <Ref. to OD(diag)15, SYSTEM CALIBRATION (REZEROING), OPERATION, Subaru Select Monitor.> CAUTION: If any of the following applies, replace the seat cushion pad and frame assembly. Do not disassemble. Cracks or deformation found in the seat cushion frame or seat cushion pad. Scratches, cracks, or deformation found on the passenger detection system pressure sensor hoses or passenger detection control module, or attachment brackets of the control module. Harness and/or connector is cracked, deformed or open. Harness wire is exposed. 2) After checking the installing condition of passengers seat, perform the system calibration of occupant detection system. <Ref. to OD(diag)-15, SYSTEM CALIBRATION (REZEROING), OPERATION, Subaru Select Monitor.>
12.BELT TENSION SENSOR

Check for the following, and replace the damaged parts with new parts. Belt tension sensor is scratched, cracked, or deformed. Harness and/or connector is cracked, deformed or open. Harness wire is exposed.
AB-13
Drivers Airbag Module

AIRBAG SYSTEM
4. Drivers Airbag Module

A: REMOVAL
CAUTION: Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB4, CAUTION, General Description.> 1) Position the front wheels straight ahead. (After moving a vehicle 5 m (16 ft) or more with front wheels positioned straight ahead, make sure that the vehicle moves straight ahead). 2) Turn the ignition switch to OFF. 3) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 4) Using TORX bit T30 (1), remove the two TORX bolts on the side of steering wheel.
B: INSTALLATION
CAUTION: Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB4, CAUTION, General Description.> To prevent the misconnection, the connector is colored. Connect the harness side connector to the same color of module side connector. Install in the reverse order of removal. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
C: INSPECTION
CAUTION: Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB4, CAUTION, General Description.> Check for the following, and replace the damaged parts with new parts. Airbag module, harness, connector and mounting bracket are damaged. <Ref. to AB-11, DRIVERS AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>
(1)
CC-00018
5) Disconnect the horn harness. 6) Disconnect the airbag connector on the back of airbag module, and then remove the airbag module. <Ref. to AB-8, PROCEDURE, Airbag Connector.>
AB-00622
7) Refer to CAUTION for handling of a removed airbag module. <Ref. to AB-4, CAUTION, General Description.>
AB-14
Passengers Airbag Module

AIRBAG SYSTEM
5. Passengers Airbag Module

A: REMOVAL
CAUTION: Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB4, CAUTION, General Description.> 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 3) Remove the instrument panel. <Ref. to EI-57, INSTRUMENT PANEL (EXCLUDING STEERING SUPPORT BEAM), REMOVAL, Instrument Panel Assembly.> 4) Remove the claw, and remove the passengers airbag module.
EI-00615
5) Refer to CAUTION for handling of a removed airbag module. <Ref. to AB-4, CAUTION, General Description.>
B: INSTALLATION
CAUTION: Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB4, CAUTION, General Description.> Install in the reverse order of removal. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
C: INSPECTION
CAUTION: Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB4, CAUTION, General Description.> Check for the following, and replace the damaged parts with new parts. Airbag module, harness, connector and mounting bracket are damaged. <Ref. to AB-12, PASSENGERS AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>
AB-15
Side Airbag Module

AIRBAG SYSTEM
6. Side Airbag Module

A: REMOVAL
CAUTION: Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB4, CAUTION, General Description.> NOTE: Remove the passengers side by referring to drivers side. 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 3) Remove the front seats. <Ref. to SE-9, REMOVAL, Front Seat.> 4) Disconnect the connector from the back side of seat cushion assembly, then remove the side airbag harness. 5) Remove the backrest cover. <Ref. to SE-10, DISASSEMBLY, Front Seat.> 6) Remove the nuts, and remove the side airbag module assembly from the back rest frame assembly.
B: INSTALLATION
CAUTION: Refer to CAUTION of General Desc

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Foreword

How to Use This Manuals

1. How to Use This Manuals

How to Use This Manuals

(3) (6) (5) (7)

(9) (10) (11) T2

(35) (27) (26) T5 (34) T3

(36) (31) T5 (29) (37) (32) (33)

: Should be lubricated with oil.

: Should be lubricated with grease.

How to Use This Manuals

15.Main Shaft Assembly for Single-Range

Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb)

(A) (B) (C)

Component Process Reference

(D) (E) (F)

Cautions Tool number of special tool Name of special tool

Tightening torque Illustration

How to Use This Manuals

How to Use This Manuals

Length Width Height

With sunroof 2.5 GT spec. B model

Reduction gear (Front) Transfer reduction Final reduction

Reduction gear (Rear)

Reduction gear (Front)

1st reduction Final reduction

Reduction gear (Rear)

3.2 10.8 (35.4) 11.6 (38.1)

Model Fuel tank

Filling amount of engine oil 2 (US qt, Imp qt)

Type and manufacturer Type and capacity (5HR) MT AT

Reduction gear (Front) Transfer reduction Final reduction

Reduction gear (Rear)

Reduction gear (Front)

1st reduction Final reduction

Reduction gear (Rear)

2.5L SOHC BASE 16 61/2JJ P225/60 R16 97H

2.5 L DOHC turbo

2.5 L SOHC model for Canada

Model Fuel tank

5.0 (5.3, 4.4)

Filling amount of engine oil 2 (US qt, Imp qt)

7.2 (7.6, 6.3)

Destination code OP code

Curb weight (C.W.)

Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.)

Front Rear Total

2. VEHICLE DYNAMICS CONTROL (VDC)

7. AIRBAG AND SEAT BELT PRETENSIONER DISPOSAL

9. AIRBAG SPECIAL TOOL

15.AIR CONDITIONER REFRIGERANT

7. LIFT AND JACK

2. STATIC ELECTRICITY DAMAGE

5. PROTECTING VEHICLE UNDER MAINTENANCE

6. ENSURING SECURITY DURING WORK

Supporting locations Pantograph jack

Swing arm lift Rigid rack

Plate lift Attachment

Front Front crossmember

Rear Rear differential